SM 57

Service
Workshop Manual
Audi 100 1991 ➤ , Audi 80 1992 ➤ ,
Audi A1 2011 ➤ ,
Audi A1 Sportback 2018 ➤ ,
Audi A2 2001 ➤ , Audi A3 1997 ➤ ,
Audi A3 2004 ➤ , Audi A3 2013 ➤ ,
Audi A3 Cabriolet 2015 ➤ ,
Audi A3 Limousine 2014 ➤ ,
Audi A3 Limousine China 2014 ➤ ,
Audi A3 Sportback China 2014 ➤ ,
Audi A4 1995 ➤ , Audi A4 2001 ➤ ,
Audi A4 2008 ➤ , Audi A4 2015 ➤ ,
Audi A4 Avant 2015 ➤ ,
Audi A4 China 2016 ➤ ,
Audi A4 allroad quattro 2016 ➤ ,
Audi A5 2016 ➤ ,
Audi A5 Coupé 2008 ➤ ,
Audi A6 1995 ➤ , Audi A6 1998 ➤ ,
Audi A6 2005 ➤ , Audi A6 2011 ➤ ,
Audi A6 2019 ➤ , Audi A6 China 2012 ➤ ,
Audi A6 China 2019 ➤ ,
Audi A8 1994 ➤ , Audi A8 2003 ➤ ,
Audi A8 2010 ➤ , Audi A8 2018 ➤ ,
Audi Cabriolet 1991 ➤ , Audi Q2 2016 ➤ ,
Audi Q2 China 2019 ➤ , Audi Q3 2012 ➤ ,
Service Department. Technical Information

Service
Audi Q3 2019 ➤ , Audi Q3 China 2013 ➤ ,

Audi Q5 2017 ➤ , Audi Q5 China 2010 ➤ ,
Audi Q7 2016 ➤ , Audi Q8 2018 ➤ ,
Audi R8 2007 ➤ , Audi R8 2015 ➤ ,
Audi TT 1999 ➤ , Audi TT 2007 ➤ ,
Audi TT 2015 ➤ , Audi e-tron 2019 ➤
Air conditioner with refrigerant R134a
Edition 05.2019
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
87 - Air conditioning system
Technical information should always be available to the foremen and mechanics,

because their careful and constant adherence to the instructions is essential to
ensure vehicle road-worthiness and safety. In addition, the normal basic safety
precautions for working on motor vehicles must, as a matter of course, be
observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2019 Audi AG, Ingolstadt A0053300220

Service
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2019 Audi AG, Ingolstadt A0053300220

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A1 Sportback 2 ...
Air conditioner with refrigerant R134a - Edition 05.2019
Contents
87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on air conditioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when handling refrigerants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 2
1.4 Safety precautions when working on vehicles with high-voltage system . . . . . . . . . . . . . . 2
1.5 Safety precautions when working in the vicinity of high-voltage components . . . . . . . . . . 3
1.6 Safety precautions when using testers and measuring instruments during a road test . . . . 4
2 General information on air conditioning systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Other reference material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Principles of air conditioning systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5 Properties of refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.6 Refrigerant oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.7 How air conditioning works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.8 General work safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.9 Product properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.10 Handling refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.11 Handling pressure vessels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.12 Basic rules for working on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.13 Before using air conditioner after system has been re-charged . . . . . . . . . . . . . . . . . . . . . . 19
3 General information on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.1 Components of refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2 Layout of components of refrigerant circuit and their influence on high-pressure and low-
pressure sides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.3 Design of refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.4 Refrigerant circuit with electrically driven air conditioner compressor . . . . . . . . . . . . . . . . 40
3.5 Connections for quick-release coupling in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . 41
3.6 Switches and senders in refrigerant circuit and related connections . . . . . . . . . . . . . . . . 47
3.7 Electrical components not installed in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.8 Pressures and temperatures in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.9 Tests and measurements performed with pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . 60
3.10 Air conditioner service and recycling units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.11 Repair notes for refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4 Laws and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.1 Laws and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5 Refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.1 Important repair notes for air conditioning systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.2 Converting refrigerant circuits from refrigerant R12 to refrigerant R134a . . . . . . . . . . . . . . 68
5.3 Working with the air conditioner service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.4 Blowing out refrigerant circuit with compressed air and nitrogen . . . . . . . . . . . . . . . . . . . . 84
5.5 Cleaning (flushing) refrigerant circuit with refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . 88
5.6 Tracing leaks in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
6 Problems with refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
6.1 Possible complaints about refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
7 Connecting air conditioner service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
7.1 Connecting air conditioner service station - vehicles with a connection on the low-pressure
and high-pressure side of the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
7.2 Connecting air conditioner service station - vehicles with no connection on the low-pressure
side of the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
8 Checking pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Contents i
8.1 Checking pressures in refrigerant circuit with air conditioner service station (with ignition
switched off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
8.2 Checking pressures - vehicles with restrictor and reservoir (with internally regulated air
conditioner compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
8.3 Checking pressures - vehicles with expansion valve and receiver (with internally regulated
air conditioner compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
8.4 Checking pressures - vehicles with restrictor, reservoir and air conditioner compressor
regulating valve N280 (with externally regulated air conditioner compressor) . . . . . . . . . . 200
8.5 Checking pressures - vehicles with expansion valve, receiver and air conditioner compressor
regulating valve N280 (with externally regulated air conditioner compressor) . . . . . . . . . . 207
8.6 Checking pressures - vehicles with electrically driven air conditioner compressor (vehicles
with high-voltage system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
9 Renewing components of refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
9.1 Renewing components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
10 Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils . . . . . . . . . . 276
10.1 Capacities for refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
10.2 Approved refrigerant oils and refrigerant oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
11 Test equipment and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
11.1 List of testers, tools and materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
11.2 Tools and materials available from regional sales centre or importer . . . . . . . . . . . . . . . . 363
11.3 Commercially available tools and materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
11.4 Improvised tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
ii Contents
87 – Air conditioning system

1 Safety precautions
(ARL006445; Edition 05.2019)
⇒ “1.1 Safety precautions when working on air conditioners”, page
1
⇒ “1.2 Safety precautions when handling refrigerants”,
page 1
⇒ “1.3 Safety precautions when working on vehicles with start/
stop system”, page 2
⇒ “1.4 Safety precautions when working on vehicles with high-
voltage system”, page 2
⇒ “1.5 Safety precautions when working in the vicinity of high-
voltage components”, page 3
⇒ “1.6 Safety precautions when using testers and measuring in‐
struments during a road test”, page 4
1.1 Safety precautions when working on air conditioners

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

Risk of irreparable damage to refrigerant lines if the inside film is
torn.
– Never bend refrigerant lines which have a radius smaller than
r = 100 mm.
1.2 Safety precautions when handling refrigerants

Danger of asphyxiation and poisoning from refrigerant
Refrigerant vapour can cause dry coughs, nausea and even as‐
phyxiation or poisoning.
– Never inhale refrigerant vapour.
– Always perform work on the refrigerant circuit and keep re‐
frigerant vessels in well ventilated areas.
– Never work in cellars, near cellar entrances or in or near other
underground areas.
– Switch on extraction systems.
1. Safety precautions 1
Risk of frostbite from refrigerant

Pressurised refrigerant can escape during work on the air condi‐
tioner. Risk of frostbite on skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Extract/drain refrigerant and then immediately open up refrig‐
erant circuit.
– Extract/drain refrigerant again if more than 10 minutes have
passed since initial extraction and refrigerant circuit has not
been opened up. Renewed evaporation has created pressure
in the refrigerant circuit.
1.3 Safety precautions when working on vehicles with start/stop system

Risk of injury - engine may start unexpectedly
The engine can start unexpectedly if the vehicle's start/stop sys‐
tem is activated. A message in the instrument cluster indicates
whether the start/stop system is activated.
– To deactivate the start/stop system, switch off the ignition.
1.4 Safety precautions when working on vehicles with high-voltage system

High voltage can cause fatal injury.
The voltage levels in the high-voltage system constitute a safety
hazard. Danger of severe or fatal injuries from electric shock or
electric arcs.
– The high-voltage system must be de-energised before any
work is performed on the high-voltage system.
– For work that does not affect the high-voltage system directly,
the high-voltage system must also be de-energised in some
cases.
– Please note the work for which the high-voltage system must
be de-energised ⇒ Rep. gr. 00 ; Assessing high-voltage sys‐
tem risk level .
– Have an Audi high-voltage technician (HVT) or an Audi high-
voltage expert (HVE) de-energise the high-voltage system.
Risk of injury - engine may start unexpectedly

It is difficult to determine whether the drive system of an electric
vehicle or hybrid vehicle is active. Moving parts can trap or draw
in parts of the body.
2 Rep. gr.87 - Air conditioning system

– Switch off ignition.

– Place ignition key outside vehicle.
Risk of injury if auxiliary air conditioner is activated

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

High voltage can cause fatal injury.
The voltage levels in the high-voltage system constitute a safety
hazard. Danger of severe or fatal injuries from electric shock or
electric arcs if high-voltage components or high-voltage wiring are
damaged.
– Carry out a visual check of high-voltage components and high-
voltage wiring.
– Never use cutting/forming tools or other sharp-edged imple‐
ments in the vicinity of high-voltage components and high-
voltage wires.
– Never perform work using welding, brazing, thermal bonding
or hot air in the vicinity of high-voltage components or high-
voltage wires.
Risk of damage to high-voltage wiring

Incorrect handling may result in damage to the insulation of high-
voltage wires or high-voltage connectors.
– Never use high-voltage wiring or high-voltage connectors as
a support.
– Never prop tools against high-voltage wiring or high-voltage
connectors.
– High-voltage cables must not be excessively bent or kinked.
– Pay attention to coding when connecting high-voltage con‐
nections.
1. Safety precautions 3
1.6 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury if test equipment is not secured
If an accident occurs and the front passenger's airbag is triggered,
test equipment which is not secured adequately may be catapul‐
ted through the vehicle with potentially serious consequences.
– Secure test equipment on the rear seat with a strap.
Or:
– Have a second mechanic operate test equipment on the rear
seat.

2 General information on air condition‐

ing systems
⇒ “2.1 Introduction”, page 5
⇒ “2.2 Other reference material ”, page 5
⇒ “2.3 Principles of air conditioning systems”, page 6
⇒ “2.4 Refrigerant R134a”, page 8
⇒ “2.5 Properties of refrigerant R134a”, page 10
⇒ “2.6 Refrigerant oil”, page 12
⇒ “2.7 How air conditioning works”, page 13
⇒ “2.8 General work safety”, page 14
⇒ “2.9 Product properties”, page 15
⇒ “2.10 Handling refrigerant”, page 15
⇒ “2.11 Handling pressure vessels”, page 16
⇒ “2.12 Basic rules for working on refrigerant circuit”, page 17
⇒ “2.13 Before using air conditioner after system has been re-
charged”, page 19
2.1 Introduction
This manual is intended to provide foremen and mechanics with
the basic knowledge needed to ensure reliable and successful
repairs.
Note
This requires careful study of the manual, coupled with suitable

training on automotive air conditioning systems (with a qualifica‐
tion test if applicable) and the ability to apply the acquired exper‐
tise in practice.
This document is a compact reference work which should be kept

at the workplace. It should also be available for presentation to
the responsible supervisory agency on request.
2.2 Other reference material

♦ Workshop Manual for model-specific maintenance work ⇒
Heating, air conditioning; Rep. gr. 87 ; Overview of fitting lo‐
cations - air conditioner (vehicle-specific Workshop Manual)
and ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations
♦ Technical Service Handbook (TPI) outlining action to be taken
to rectify current problems
♦ Self-study programmes, e.g. ⇒ Self-study programme No.
208 ; Air conditioning systems in motor vehicles
♦ Video training courses for dealerships
♦ List of special tools and workshop equipment required for re‐
pairing the air conditioner ⇒ Electronic parts catalogue (Tools;
Workshop equipment/tools; Air conditioner/heater).
♦ Service Organisation Handbook, Vol. 1 “Additional equipment”
⇒ Audi ServiceNet, Handbooks
2. General information on air conditioning systems 5

♦ Workshop Manual: Air conditioner with refrigerant R12 (for

vehicles built up to model year 1993; this Workshop Manual is
available in hardcopy form only)
2.3 Principles of air conditioning systems

⇒ “2.3.1 Physical principles”, page 6
⇒ “2.3.2 Pressure and boiling point”, page 6
⇒ “2.3.3 Vapour pressure table for refrigerant R134a”,
page 7
⇒ “2.5 Properties of refrigerant R134a”, page 10
2.3.1 Physical principles

The four familiar states of water apply to air conditioning refriger‐
ants, too.
1- Gas (invisible)
2- Vapour
3- Liquid
4- Solid
When water is heated in a vessel (heat absorption), water vapour

can be seen to rise. If the vapour is further heated through heat
absorption, the visible vapour turns into invisible gas. The process
is reversible. If heat is extracted from gaseous water -A-, it
changes first to vapour -B-, then to water and finally to ice.
A - Heat absorption
B - Heat emission
Heat always flows from a warmer to a colder substance
Every substance consists of a mass of moving molecules. The
fast-moving molecules of a warmer substance give off some of
their energy to the cooler and thus slower molecules. As a result,
the molecular motion of the warmer substance slows down and
that of the colder substance is accelerated. This process contin‐
ues until the molecules of both substances are moving at the
same speed. They are then at the same temperature and no fur‐
ther heat exchange takes place.
2.3.2 Pressure and boiling point

The boiling point given in tables for a liquid is always referenced
to an atmospheric pressure of 1 bar. If the pressure acting on a
liquid changes, its boiling point also changes.

Note
Pressure can be measured in various units: 1 MPa (megapascal)

is equivalent to 10 bar gauge pressure, or 145 psi; 1 bar absolute
pressure is the same as 0 bar gauge pressure, which is roughly
equivalent to atmospheric pressure.
For example, water boils at a lower temperature the lower the

pressure.
The vapour pressure curves for water and refrigerant R134a
show, for example, that, at constant pressure, reducing the tem‐
perature changes vapour to liquid (in the condenser) or that, for
instance, reducing the pressure causes the refrigerant to change
from liquid to vapour (in the evaporator).
Vapour pressure curve for water
A - Liquid
B - Gaseous
C - Vapour pressure curve for water
1 - Pressure acting on liquid in bar (absolute)
2 - Temperature in °C
Vapour pressure curve for refrigerant R134a

A - Liquid
B - Gaseous
D - Vapour pressure curve for refrigerant R134a
1 - Pressure acting on liquid in bar (absolute)
2 - Temperature in °C
2.3.3 Vapour pressure table for refrigerant

R134a
The vapour pressure table for every refrigerant is published in the
literature for refrigeration system engineers. This table makes it
possible to determine the vapour pressure acting on the column
of liquid in a vessel if the temperature of the vessel is known.
As there is a characteristic vapour pressure table for every refrig‐
erant, it is possible to identify the type of refrigerant by measuring
pressure and temperature.

Note
♦ “0 bar absolute pressure” corresponds to an absolute vacuum.

The normal ambient pressure (atmospheric pressure) corre‐
sponds to approx. “1 bar absolute pressure”. On the scales of
most pressure gauges, “0 bar” corresponds to an absolute
pressure of 1 bar (this is also indicated by the value “-1” ap‐
pearing below “0”).
♦ Pressure can be measured in various units: 1 MPa (mega‐
pascal) is equivalent to 10 bar gauge pressure, or 145 psi; 1
bar absolute pressure is the same as 0 bar gauge pressure,
which is roughly equivalent to atmospheric pressure.
Temperature in °C Pressure in bar (gauge pres‐

sure), R134a
-45 -0.61
-40 -0.49
-35 -0.34
-30 -0.16
-25 0.06
-20 0.32
-15 0.63
-10 1.00
-5 1.43
0 1.92
5 2.49
10 3.13
15 3.90
20 4.70
25 5.63
30 6.70
35 7.83
40 9.10
45 10.54
50 12.11
55 13.83
60 15.72
65 17.79
70 20.05
75 22.52
80 25.21
85 28.14
90 31.34
2.4 Refrigerant R134a

Air conditioning systems in vehicles use a vaporisation and con‐
densation process. These systems employ a substance with a
low boiling point, referred to as refrigerant.
The refrigerant used is tetrafluoroethane or R134a, which boils at
-26.5°C at a vapour pressure of “1 bar absolute pressure” (cor‐
responds approx. to ambient pressure).

⇒ “2.4.1 Physical properties of refrigerant R134a”, page 9

⇒ “2.4.2 Critical point”, page 9
⇒ “2.4.3 Environmental aspects of refrigerant R134a”,
page 9
2.4.1 Physical properties of refrigerant R134a

Chemical formula CH2F–CF3 or CF3–CH2F
Chemical designation Tetrafluoroethane
Boiling point at 1 bar -26.5 °C
Solidification point -101.6 °C
Critical temperature 100.6 °C
Critical pressure 40.56 bar (absolute)
2.4.2 Critical point

The critical point (critical temperature and critical pressure) is the
point above which there is no longer a boundary between liquid
and gas.
A substance above its critical point is always in the gaseous state.
At temperatures below the critical point, all types of refrigerant in
pressure vessels exhibit both a liquid and a gas phase, i.e. there
is a layer of gas above the liquid.
As long as both liquid and gas are present in the vessel, the pres‐
sure is governed by ambient temperature ⇒ page 7 “Vapour
pressure table”.
Note
Different types of refrigerant must never be mixed. The refrigerant

specified for the respective air conditioning system must be used
exclusively.
2.4.3 Environmental aspects of refrigerant

R134a
♦ R134a is a fluorocarbon and contains no chlorine.
♦ R134a has a shorter atmospheric lifespan than refrigerant
R12.
♦ R134a does not damage the ozone layer; the ozone-depleting
potential is zero.
♦ The global warming potential (GWP) of R134a is approx. 1400
(GWP of carbon dioxide = 1). To reduce the impact of refrig‐
erant R134a on global warming, the European Commission
has ruled that vehicles with air conditioners using refrigerant
with a GWP higher than 150 may no longer be made available
on the market from 1 January 2017 onwards. Air conditioners
in vehicles which were made available on the market before
31 December 2016 may be filled and operated with refrigerant
R134a until further notice.
♦ The global warming effect of R134a is ten times less than that
of refrigerant R12.

2.5 Properties of refrigerant R134a

⇒ “2.5.1 Trade names and designations”, page 10
⇒ “2.5.2 Colour”, page 10
⇒ “2.5.3 Vapour pressure”, page 10
⇒ “2.5.4 Physical properties of R134a”, page 10
⇒ “2.5.5 Reaction with metals”, page 11
⇒ “2.5.6 Critical temperature/critical pressure”, page 11
⇒ “2.5.7 Water content”, page 11
⇒ “2.5.8 Combustibility”, page 11
⇒ “2.5.9 Charge factor”, page 11
⇒ “2.5.10 Tracing leaks”, page 11
2.5.1 Trade names and designations

The refrigerant R134a is currently available under the following
trade names:
♦ H-FKW 134a
♦ SUVA 134a
♦ KLEA 134a
Note
♦ Different trade names may be used in other countries.

♦ Of the wide range of refrigerants available, this is the only one
which may be used for vehicles. The designations Frigen and
Freon are trade names. They also apply to refrigerants which
should not be used in vehicles.
2.5.2 Colour
Like water, refrigerants are colourless in both vapour and liquid
form. Gas is invisible. Only the boundary layer between gas and
liquid is visible (liquid level in tube of charging cylinder or bubbles
in a sight glass). Liquid refrigerant R134a may have a coloured
(milky) appearance in a sight glass. This cloudiness is caused by
partially dissolved refrigerant oil and does not indicate a fault.
2.5.3 Vapour pressure

In a partially filled, closed vessel, the quantity of refrigerant evap‐
orating from the surface equals the quantity returning to the liquid
state as vapour particles condense. This state of equilibrium oc‐
curs when the system is pressurised and is often called vapour
pressure. Vapour pressure is dependent on temperature
⇒ page 7 “Vapour pressure table”.
2.5.4 Physical properties of R134a

As the vapour pressure curves of R134a and other refrigerants
are sometimes very similar, a clear identification is not possible
based merely on the pressure.
When using R134a, the air conditioner compressor is lubricated
with special synthetic refrigerant oils, e.g. PAG oils (polyalkylene
glycol oils).

2.5.5 Reaction with metals

In its pure state, refrigerant R134a is chemically stable and does
not corrode iron or aluminium.
However, refrigerant impurities such as chlorine compounds
cause corrosion of certain metals and plastics. This can cause
blockages, leaks and deposits on the air conditioner compressor
piston.
2.5.6 Critical temperature/critical pressure

The refrigerant R134a remains chemically stable up to a gas
pressure of 39.5 bar (40.56 bar absolute pressure; corresponds
to a temperature of 101 °C). Above this temperature, the refrig‐
erant decomposes (see "Combustibility").
2.5.7 Water content

Only very small amounts of water are soluble in liquid refrigerant.
In contrast, refrigerant vapour and water vapour mix in any ratio.
Any water in the refrigerant circuit will be entrained in droplet form
once the dryer in the receiver or reservoir has absorbed approx.
7 g of water. This water flows as far as the expansion valve nozzle
or the restrictor and turns to ice. The air conditioner will then no
longer provide any cooling effect.
Water causes irreparable damage to the air conditioner because
at high pressures and temperatures it combines with other im‐
purities to form acids.
2.5.8 Combustibility
Refrigerant is non-flammable. In fact it has a fire-inhibiting or fire-
extinguishing effect. Refrigerant decomposes when exposed to
flames or red-hot surfaces. UV light (produced for example during
electric welding) also causes refrigerant decomposition. The re‐
sultant decomposition products are toxic and must not be inhaled.
However, these chemicals irritate the mucous membranes, giving
adequate warning of their presence.
2.5.9 Charge factor

A container must have space for vapour as well as liquid. As the
temperature rises, the liquid expands. The vapour-filled space
becomes smaller. At a certain point, there will only be liquid in the
vessel. Beyond this, even a slight increase in temperature causes
great pressure to build up in the vessel as the liquid attempts to
continue expanding despite the absence of the necessary space.
The resultant forces are sufficient to rupture the vessel. To stop
containers being overfilled, regulations governing the storage of
compressed gases specify the number of kilograms of refrigerant
with which a container may be filled per litre of internal volume.
The maximum permissible capacity is calculated by multiplying
this "charge factor" by the internal volume of the vessel. The
charge factor for refrigerant used in motor vehicles is 1.15 kg/litre.
2.5.10 Tracing leaks

External damage, for example, can cause a leak in the refrigerant
circuit. Minor leaks where only a small amount of refrigerant is
escaping can be detected using, for example, an electronic leak
detector or by adding a UV leak detection additive to the refrig‐
erant circuit. Electronic leak detectors are capable of registering
leaks with refrigerant losses of less than 5 g per year.

Note
It is important to use leak detectors that are designed for the

composition of the respective refrigerant type. For example, a
leak detector for R12 refrigerant is not suitable for R134a refrig‐
erant because R134a has no chlorine atoms and the leak detector
therefore does not respond.
2.6 Refrigerant oil
Caution
♦ For information on how to handle refrigerant oil, refer to ⇒

Audi ServiceNet, HSO Environmental Protection (or ⇒
Volkswagen ServiceNet, Handbooks, Service Handbook;
Environmental Protection ) and observe local regulations.
Refrigerant oil mixes with the refrigerant (in a ratio of about

20 - 40 %, depending on compressor type and quantity of refrig‐
erant) and circulates constantly in the system, lubricating the
moving parts.
Special synthetic refrigerant oils, e.g. polyalkylene glycol (PAG)
oil, are used in conjunction with R134a air conditioning systems.
This is necessary as mineral oil, for example, does not mix with
R134a. In addition, the materials of the R134a air conditioning
system could be corroded as a result of mixture flowing through
the refrigerant circuit under pressure at high temperatures or
breakdown of the lubricating film in the air conditioner compres‐
sor. The use of non-approved oils can lead to the failure of the air
conditioning system, so it is important to use only the approved
types of oil.
⇒ Electronic parts catalogue.
Type of oil for R134a in motor vehicles: PAG (polyalkylene-glycol)
Note
♦ Do not store refrigerant oil in open containers as it is extremely

hygroscopic (it attracts water).
♦ Always keep oil containers sealed.
♦ Do not re-use old refrigerant oil. Refrigerant oil must be dis‐
posed of as used oil of unknown origin (observe local regula‐
tions) ⇒ Audi ServiceNet, HSO Environmental Protection (or
⇒ Volkswagen ServiceNet, Handbooks, Service Handbook;
Environmental Protection ).
♦ Ester-based oils are currently only intended for use with large
systems (not for motor vehicle air conditioners).
⇒ “2.6.1 Properties of refrigerant oil”, page 12
2.6.1 Properties of refrigerant oil

The most important properties are a high degree of solubility with
refrigerant, good lubricity, absence of acid and minimal water
content. It is therefore only permissible to use certain oils. For a
list of approved refrigerant oils and capacities, refer to
⇒ page 317 .
PAG oils for refrigerant R134a are highly hygroscopic and do not
mix with other oils. Opened containers should therefore be closed
again immediately to prevent moisture from entering. Moisture

and acids cause refrigerant oil to age, making it dark, viscous and
corrosive to metals.
Note
♦ Due to its chemical properties, refrigerant oil must not be dis‐

posed of together with engine oil or gear oil. Refrigerant oil
must be disposed of as used oil of unknown origin (observe
local regulations) ⇒ Audi ServiceNet, HSO Environmental
Protection (or ⇒ Volkswagen ServiceNet, Handbooks, Service
Handbook; Environmental Protection ).
♦ Only oil approved for the air conditioner compressor may be
used for refrigerant circuits containing refrigerant R134a ⇒
Electronic parts catalogue and capacities ⇒ page 317 .
Important information:
As refrigerant oil is extremely hygroscopic, open containers must
be closed and re-sealed immediately after use to prevent mois‐
ture from entering.
Note
♦ A use-by date for the refrigerant oil is stated on the bottle in

which the refrigerant oil is supplied.
♦ This date is not relevant if the bottle is sealed air-tight.
♦ If the bottle is sealed air-tight, the refrigerant oil can also be
used after the date stated on the bottle.
2.7 How air conditioning works

The temperature in the passenger compartment depends on the
amount of heat radiated into the vehicle through the windows and
conducted by the metal parts of the body. In hot weather some of
the heat must be pumped off to achieve a more comfortable tem‐
perature for the occupants.
As heat is always transmitted away from warmer areas and into
cooler areas, the passenger compartment is fitted with a unit for
generating low temperatures in which refrigerant is constantly
evaporated. The heat required for this is extracted from the air
flowing through the evaporator.
After absorbing heat, the refrigerant is pumped off by the air con‐
ditioner compressor. Thanks to the action of the compressor, the
heat content and temperature of the refrigerant increases. Its
temperature is then substantially higher than that of the surround‐
ing air.
The hot refrigerant flows with its heat content to the condenser.
where the refrigerant dissipates its heat to the surrounding air via
the condenser due to the temperature gradient between the re‐
frigerant and the surrounding air.
The refrigerant thus acts as a heat transfer medium. As it will be
needed again, the refrigerant is returned to the evaporator.
For this reason all air conditioning systems are based on the re‐
frigerant circulation principle. There are however differences as
regards the units used.

⇒ “2.7.1 Comfort of vehicle occupants”, page 14

⇒ “2.7.2 Environmental aspects”, page 14
2.7.1 Comfort of vehicle occupants

A basic requirement for safety and concentration while driving is
a feeling of comfort in the passenger compartment. Especially
when conditions are hot and humid, a good level of comfort can
only be achieved with air conditioning. Passenger comfort can of
course also be improved by opening the windows or sun roof, or
by increasing the air flow. This, however, involves several draw‐
backs for the occupants, e.g. more noise, draughts, exhaust
fumes and unfiltered pollen (unpleasant for allergy sufferers).
Climate control together with a good heating and ventilation sys‐
tem can create a sense of well-being and comfort by regulating
temperature, humidity and air circulation in the passenger com‐
partment to suit ambient conditions, both when the vehicle is
stationary and when it is moving.
Other important advantages of air conditioning:
♦ Filtration of the air supplied to the passenger compartment
(dust and pollen, for example, are washed out by the moist fins
of the evaporator and discharged with the condensation).
♦ Pleasant temperature levels (example: mid-size car after short
travelling time, ambient temperature 30 °C in the shade and
vehicle exposed to sunlight)
With air conditioning Without air condi‐
tioning
At head height 23 °C 42 °C
At chest level 24 °C 40 °C
In footwell 30 °C 35 °C
2.7.2 Environmental aspects

Since about 1992, the air conditioning systems of newly manu‐
factured cars have been successively changed to refrigerant
R134a. This refrigerant contains no chlorine and therefore does
not deplete the ozone layer.
Up until roughly 1992, refrigerant R12 was used for air condition‐
ing systems. Due to its chlorine atoms, this CFC had a high ozone
depletion potential as well as potential for intensifying the green‐
house effect.
Conversion programmes are available for old existing systems
filled with the ozone-depleting substance R12 ⇒ Workshop Man‐
ual for air conditioners with refrigerant R12 (this Workshop Man‐
ual is available in hardcopy form only).
The global warming potential (GWP) of R134a is approx. 1400;
the European Commission has therefore ruled that vehicles using
this refrigerant may no longer be made available on the market
from 1 January 2017 onwards ⇒ page 9 . From 2016 onwards,
refrigerant with a GWP of less than 150 will be used for newly
manufactured vehicles (e.g. refrigerant R1234yf with a GWP of
less than 5).
For environmental reasons, refrigerants must not be released into
the atmosphere ⇒ page 63 (see the relevant environmental leg‐
islation).
2.8 General work safety

♦ In accordance with regulations of the German industrial liabil‐
ity insurance association, VBG 20, (other regulations may
apply in other countries)

♦ Observe specific instructions relating to workplaces where re‐

frigerants are handled ⇒ Audi-ServiceNet, HSO Environmen‐
tal Protection . These instructions must be posted at the
workplace.
2.9 Product properties

Refrigerants used in motor vehicle air conditioning systems be‐
long to the new generation of refrigerants based on chlorine-free,
partially fluorinated hydrocarbons (H-FKW, R134a; other names
may be used in other countries).
With regard to their physical properties, these are refrigerants
which have been liquefied under pressure. They are subject to
the regulations governing pressure vessels and may only be used
in approved and appropriately marked containers.
Specific requirements must be observed to ensure safe and prop‐
er handling:
2.10 Handling refrigerant

If refrigerant vessels are opened, the contents may escape in liq‐
uid or vapour form. The higher the pressure in the vessel, the
more vigorous the process.
The pressure level is governed by two factors:
• The type of refrigerant in the vessel. “Rule: The lower the boil‐
ing point, the higher the pressure.”
• The temperature level. “Rule: The higher the temperature, the
higher the pressure.”
WARNING
♦ Risk of injury (frostbite).

♦ The refrigerant may escape as liquid or vapour.
♦ Do not open vessels containing refrigerant.
Wear safety goggles.

Put on safety goggles to prevent refrigerant getting into the eyes,
as this could cause severe injury through frostbite.
Wear protective gloves and apron.
Grease and oils dissolve readily in refrigerants. They would there‐
fore damage the protective layer of grease if allowed to come into
contact with the skin. Degreased skin is however sensitive to the
cold and germs.
Do not allow liquid refrigerant to come into contact with the skin
The refrigerant draws heat for evaporation from the surrounding
area - even if this is the skin. This may give rise to extremely low
temperatures and result in local frostbite (boiling point of R134a:
-26.5 °C at ambient pressure).
Do not inhale refrigerant vapours
If refrigerant vapour escapes in concentrated form, it mixes with
the surrounding air and displaces the oxygen necessary for
breathing.
Smoking is absolutely prohibited
A burning cigarette can cause refrigerant to decompose. The re‐
sultant substances are toxic and must not be inhaled.

Welding and soldering on refrigeration systems

Before performing welding, brazing or soldering work on vehicles
in the vicinity of air conditioning system components, extract re‐
frigerant and remove any remaining refrigerant by blowing out
with nitrogen.
The products of refrigerant decomposition due to the effect of heat
are not only toxic, but may also have a highly corrosive effect on
pipes and system components. The principal substance is hydro‐
gen fluoride.
Pungent odour
A pungent odour indicates that the products of decomposition
mentioned above have already formed. Do NOT inhale these
substances, otherwise the respiratory tract, lungs and other or‐
gans could be damaged.
First aid
• Following accidental contact with eyes or mucous mem‐
branes, immediately rinse with copious amounts of running
water and consult an eye specialist.
• Following accidental contact with the skin, immediately re‐
move clothing affected and rinse skin with copious amounts of
water.
• Following accidental inhalation of concentrated refrigerant va‐
pours, the person concerned must be taken immediately into
the open air. Call a doctor. Administer oxygen in the event of
breathing difficulties. If the person affected is having great dif‐
ficulty breathing or is not breathing at all, tilt back head and
administer artificial respiration.
⇒ “2.11 Handling pressure vessels”, page 16
2.11 Handling pressure vessels

Secure vessels to prevent them falling over.
Secure upright cylinders to stop them falling over and cylinders
lying flat to stop them rolling away.
Pressure vessels must never be thrown.
If dropped, the vessels could be so severely deformed that they
rupture. The refrigerant evaporates immediately, liberating con‐
siderable force. Flying fragments of cylinders can cause severe
injuries.
To protect the valves, cylinders may only be transported with the
protective cap screwed on.
Valves may break off if cylinders are not properly transported.
Never store in the vicinity of radiators.
High temperatures may occur in such areas. High temperatures
are also accompanied by high pressures and the maximum per‐
missible vessel pressure may be exceeded.
Do not heat to temperatures above 50 °C
To avoid possible risk, pressure vessel regulations specify that
vessels must not be heated to temperatures exceeding 50 °C.
Do not heat in an uncontrolled manner
Do NOT heat with a naked flame. Local overheating can cause
structural changes in the material of the vessel, which then reduce
its ability to withstand pressure. There is also a danger of refrig‐
erant decomposition due to localised overheating.

Sealing empty vessels

Empty refrigerant vessels must always be sealed to prevent mois‐
ture from entering. Moisture can cause steel vessels to rust. This
weakens the vessel walls. In addition, any rust particles which
enter refrigeration systems from storage vessels will cause mal‐
functioning.
2.12 Basic rules for working on refrigerant cir‐

cuit
⇒ “2.12.1 General notes”, page 17
⇒ “2.12.2 Cleaning refrigerant circuit”, page 17
⇒ “2.12.3 Additionally for vehicles with air conditioner compressor
without magnetic clutch (with air conditioner compressor regulat‐
ing valve N280 only)”, page 18
⇒ “2.12.4 Additional information on vehicles with high-voltage
system”, page 18
⇒ “2.12.5 O-rings”, page 19
2.12.1 General notes

• Observe specific instructions relating to workplaces ⇒ Audi
ServiceNet, HSO Environmental Protection .
• Ensure absolute cleanliness when working.
• Wear safety goggles and gloves when working with refrigerant
and nitrogen.
• Switch on the available workshop exhaust extraction systems.
• Always use air conditioner service station to discharge refrig‐
erant circuit, then unfasten screw connections and renew
defective components.
• Use caps to seal off opened components and hoses to prevent
moisture and dirt from entering the system.
• Use only tools and materials intended for refrigerant R134a.
• Seal opened refrigerant oil containers to guard against mois‐
ture.
Note
♦ After completing service work, screw sealing caps (with seals)

onto service connections and all connections with valves.
♦ Before starting up air conditioning system, check specified ca‐
pacity for vehicle ⇒ page 276 .
♦ Do not top up refrigerant in circuit; discharge existing refriger‐
ant and re-charge system.
2.12.2 Cleaning refrigerant circuit

The refrigerant circuit must be cleaned (flushed) with refrigerant
R134a ⇒ page 88 (or blown out with compressed air and nitro‐
gen ⇒ page 84 ) in the following cases:
– If moisture or dirt has entered the refrigerant circuit (e.g. fol‐
lowing an accident)
– If the refrigerant oil is dark and viscous
– If there is too much refrigerant oil in the refrigerant circuit after
renewing compressor

– If the air conditioner compressor has to be renewed due to

“internal” damage (e.g. noise or no output)
Note
When blowing out components with compressed air and nitrogen,

always extract the gas mixture escaping from the components
with suitable extraction units (workshop extraction system).
2.12.3 Additionally for vehicles with air condi‐

tioner compressor without magnetic
clutch (with air conditioner compressor
regulating valve - N280- only)
• Only start the engine after the refrigerant circuit has been as‐
sembled completely (constant air conditioner compressor op‐
eration).
• If the engine has to be operated with the refrigerant circuit
empty, only do so for as long as absolutely essential and avoid
increased engine speeds.
2.12.4 Additional information on vehicles with

high-voltage system
Vehicles with high-voltage system (hybrid vehicles)
♦ For further information on the high-voltage system, refer to ⇒
Rep. gr. 00 ; Safety precautions or ⇒ Electrical system; Rep.
gr. 93 ; General warning instructions for work on the high-
voltage system .
♦ If work on high-voltage system components is necessary, de-
energise high-voltage system ⇒ Rep. gr. 00 ; Safety precau‐
tions or ⇒ Electrical system; Rep. gr. 93 ; General warning
instructions for work on the high-voltage system .
• The engine should only be started after the refrigerant circuit
has been assembled completely.
• On vehicles with battery cooling, hybrid operation is only pos‐
sible with the air conditioner charged and with no air condi‐
tioner faults stored ⇒ Vehicle diagnostic tester in “Guided
Fault Finding” mode for air conditioner and battery regulation
• After installing the electrically driven air conditioner compres‐
sor and then charging the refrigerant circuit, first start up the
compressor via the “Compressor run-in” function of the basic
setting routine. Otherwise, the air conditioner compressor may
be damaged if refrigerant oil has accumulated in the compres‐
sion chamber of the air conditioner compressor due to inap‐
propriate storage prior to installation. ⇒ Vehicle diagnostic
tester, “Guided Fault Finding” function for air conditioner and
battery regulation
• An electrically driven air conditioner compressor may only be
activated when the refrigerant circuit is charged. Running the
air conditioner compressor with the refrigerant circuit empty
could lead to compressor damage ⇒ Vehicle diagnostic tester
(“Guided Fault Finding” mode for air conditioner and battery
regulation) .
• Before the refrigerant circuit can be discharged, evacuated
and charged, specific electrically operated valves (may vary
depending on the refrigerant circuit layout) must be opened
(e.g. on the Audi Q7 e-tron) ⇒ Heating, air conditioning; Rep.
gr. 87 ; Refrigerant circuit and ⇒ Vehicle diagnostic tester in
“Guided Fault Finding” mode.

• To check whether the air conditioner is functioning properly,

specific electrically operated valves must be opened or closed
(e.g. on the Audi Q7 e-tron) ⇒ Heating, air conditioning; Rep.
gr. 87 ; Refrigerant circuit and ⇒ Vehicle diagnostic tester in
• Depending on the vehicle, high pressure may not be available
at the service connection on the high-pressure side in all air
conditioner operating modes (e.g. on the Audi Q7 e-tron). The
senders installed in the refrigerant circuit must therefore be
used to check that the air conditioner in these vehicles is func‐
tioning properly ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit and ⇒ Vehicle diagnostic tester in “Guided
Fault Finding” mode.
– To minimise the number of automatic engine starts when the
vehicle's drive system is active during test and measurement
work, charge the vehicle batteries e.g. with the battery
charger 60A - VAS 5904- in battery standby mode ⇒ Electrical
system; General information; Rep. gr. 27 ; Charging battery
and ⇒ Electrical system; Rep. gr. 93 ; General warning in‐
structions for work on the high-voltage system .
– For test and measurement work that requires the vehicle's
drive system to be active (READY) or the ignition to be switch‐
ed on, move the selector lever to position “P”, activate the
parking brake and take care to keep well clear of the engine
when it is running. Set up any tools needed so that they cannot
come into contact with moving parts.
2.12.5 O-rings
♦ Use only seals which are resistant to refrigerant R134a and
the corresponding refrigerant oils. Colour coding of O-ring
seals is no longer employed. Black and coloured O-rings are
used.
♦ Note the correct inside diameter of the seals used ⇒ Electronic
parts catalogue , ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit (vehicle-specific Workshop Manual).
♦ Seals may only be used once.
♦ Before fitting, lightly lubricate seals with refrigerant oil (PAG
oil).
2.13 Before using air conditioner after system

has been re-charged
Mechanically driven air conditioner compressor
After air conditioner compressor is attached to engine (before belt
is fitted or drive shaft is installed)
⇒ “5.3.6 Starting up air conditioner after charging”, page 81 and
⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐
pressor .
– Rotate air conditioner compressor about 10 revolutions by
hand using the magnetic clutch pulley or belt pulley.
After re-charging
⇒ “5.3.6 Starting up air conditioner after charging”, page 81
– Start engine with air conditioner switched off ( air conditioning
system magnetic clutch - N25- and air conditioner compressor
regulating valve - N280- are not activated).
– When engine idling speed has stabilised, switch on air condi‐
tioner compressor and run it for at least 10 minutes at idling
speed with maximum cooling output.

Electrically driven air conditioner compressor

– After charging the refrigerant circuit, start the electrically driv‐
en air conditioner compressor first using the “Compressor run-
in” function of the basic setting
⇒ “5.3.6 Starting up air conditioner after charging”,
page 81 and ⇒ Vehicle diagnostic tester, “Guided Fault
Finding” function for air conditioner and battery regulation

3 General information on refrigerant

circuit
⇒ “3.1 Components of refrigerant circuit”, page 21
⇒ “3.2 Layout of components of refrigerant circuit and their influ‐
ence on high-pressure and low-pressure sides”, page 21
⇒ “3.3 Design of refrigerant circuit”, page 39
⇒ “3.4 Refrigerant circuit with electrically driven air conditioner
compressor”, page 40
⇒ “3.5 Connections for quick-release coupling in refrigerant cir‐
cuit”, page 41
⇒ “3.6 Switches and senders in refrigerant circuit and related
connections ”, page 47
⇒ “3.7 Electrical components not installed in refrigerant circuit”,
page 55
⇒ “3.8 Pressures and temperatures in refrigerant circuit”,
page 55
⇒ “3.9 Tests and measurements performed with pressure gauge”,
page 60
⇒ “3.10 Air conditioner service and recycling units”, page 61
⇒ “3.11 Repair notes for refrigerant circuit”, page 62
3.1 Components of refrigerant circuit
Caution
Tools or materials (e.g. sealing additives) that have not been

approved can damage or impair the system.
Use only tools and materials that have been approved by the
manufacturer.
Warranty claims are not accepted if tools or materials that have
not been approved are used.
• All components of the refrigerant circuit submitted for quality

analysis should always be sealed (use original sealing caps of
replacement part).
• Renew damaged or leaking components of refrigerant circuit
⇒ page 258 .
Note
The following replacement parts were previously filled with nitro‐

gen gas: air conditioner compressor, reservoir, evaporator and
condenser. This charge is being gradually discontinued. There‐
fore, little or no pressure equalisation can be perceived when the
sealing plugs of the replacement part are unscrewed.
3.2 Layout of components of refrigerant cir‐

cuit and their influence on high-pressure
and low-pressure sides
High-pressure side: Condenser, receiver and restrictor or expan‐
sion valve to separate the high and low-pressure liquid ends.
3. General information on refrigerant circuit 21

High pressure results from the restrictor or expansion valve form‐

ing a constriction and causing the refrigerant to build up, thus
leading to an increase in pressure and temperature.
Excess pressure occurs if too much refrigerant or refrigerant oil
is used, the condenser is contaminated, the radiator fan is defec‐
tive, the system is blocked or in the event of moisture in the
refrigerant circuit (icing-up of restrictor or expansion valve).
Low-pressure side: Evaporator, evaporator temperature sensor
and air conditioner compressor to separate the sections with high
and low gas pressure.
A drop in system pressure can be caused by a loss of refrigerant,
the restrictor or expansion valve (constrictions), a defective air
conditioner compressor or an iced-up evaporator.

⇒ “3.2.1 Mechanically driven air conditioner compressor”,

page 23
⇒ “3.2.2 Electrically driven air conditioner compressor for vehicles
with a high-voltage system”, page 25
⇒ “3.2.3 Condenser”, page 27
⇒ “3.2.4 Evaporator”, page 27
⇒ “3.2.5 Heat exchanger for heat pump operation”, page 28
⇒ “3.2.6 Fluid collector”, page 28
⇒ “3.2.7 Reservoir”, page 29
⇒ “3.2.8 Restrictor”, page 29
⇒ “3.2.9 Receiver”, page 31
⇒ “3.2.10 Expansion valve”, page 32
⇒ “3.2.11 Expansion valve with shut-off valve”, page 32
⇒ “3.2.12 Refrigerant shut-off valves”, page 33
⇒ “3.2.13 Refrigerant line with internal heat exchanger”,
page 35
⇒ “3.2.14 Quick-release couplings on refrigerant line”,
page 35
⇒ “3.2.15 O-rings”, page 37
⇒ “3.2.16 Pipes and hoses of refrigerant circuit”, page 37
⇒ “3.2.17 High-pressure safety valve”, page 37
⇒ “3.2.18 Non-return valves”, page 38
3.2.1 Mechanically driven air conditioner com‐

pressor
The air conditioner compressor is driven by the engine via a poly
V-belt or a drive shaft.
Air conditioner compressor with magnetic clutch:
♦ An electromagnetic clutch -A- attached to the air conditioner
compressor provides the power link between the pulley -B-
and the compressor crankshaft when the air conditioning is
switched on.
♦ An overload protection attached to the clutch plate or fitted in
the solenoid of the air conditioner compressor is triggered if
the air conditioner compressor is not running smoothly in order
to protect the belt drive against overload.
Air conditioner compressor with no magnetic clutch:
♦ An overload protection attached to the pulley -B- or fitted in the
drive unit of the air conditioner compressor is triggered if the
air conditioner compressor is not running smoothly in order to
protect the belt drive against overload.
All air conditioner compressors
The air conditioner compressor draws in refrigerant gas from the
evaporator, compresses it and conveys it to the condenser.

Note
♦ The air conditioner compressor contains refrigerant oil which

mixes with refrigerant R134a at all temperatures.
♦ The type plate indicates the refrigerant for which the air con‐
ditioner compressor is designed. A valve regulates the pres‐
sure on the low-pressure side within the specified range
(control characteristic).
♦ At present, actuation is effected externally by way of a regu‐
lating valve -C- on air conditioner compressors with or without
magnetic clutch.
♦ On air conditioner compressors with no magnetic clutch, the
engine is only to be started following complete assembly of the
refrigerant circuit.
♦ To prevent air conditioner compressor damage if the refriger‐
ant circuit is empty, the magnetic clutch is deactivated and the
air conditioner compressor regulating valve - N280- no longer
actuated (air conditioner compressor idles with engine).
♦ If the refrigerant circuit is empty, an air conditioner compressor
with no air conditioning system magnetic clutch - N25- (with
air conditioner compressor regulating valve - N280- ) is switch‐
ed to internal lubrication by way of a valve.
♦ Depending on the version of the air conditioner compressor,
there may be a valve on the high-pressure side of the com‐
pressor which prevents liquid refrigerant from flowing back into
the compressor after the air conditioner has been switched off.
If an air conditioner compressor with such a valve is installed
in a vehicle with a refrigerant circuit with an expansion valve,
it may take a relatively long time before the pressure in the
high-pressure side drops (the expansion valve is cold and the
pressure in the low-pressure side increases rapidly after the
compressor is switched off; the expansion valve is closed and
the refrigerant can only flow slowly to the low-pressure side).
If the air conditioner compressor is switched on, the pressure
in the low-pressure side drops, the expansion valve is opened
and the refrigerant can flow to the low-pressure side.
♦ On air conditioner compressors with an electromagnetic clutch
-A- and a regulating valve -C-, the electromagnetic clutch -A-
is usually only activated in conjunction with regulating valve
-C- ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant cir‐
cuit .

3.2.2 Electrically driven air conditioner com‐

pressor for vehicles with a high-voltage
system
WARNING
Danger of short circuit

The air conditioner compressor operates at up to 288 V in a
speed range between 800 and 8600 rpm.
Avoid contact with the air conditioner compressor when switch‐
ing on the ignition or starting the drive units - danger of short
circuit.
♦ The air conditioner compressor draws in refrigerant gas from

the evaporator, compresses it and conveys it to the condens‐
er.
♦ The electric motor of the air conditioner compressor is sup‐
plied with power by the power and control electronics for
electric drive - JX1- .
♦ The control unit for air conditioning compressor - J842- inte‐
grated in the air conditioner compressor regulates the speed
and thereby the output of the air conditioner compressor ( elec‐
trical air conditioner compressor - V470- ) based on the re‐
quest received via the data bus ⇒ Vehicle diagnostic tester,
“Guided Fault Finding” function for air conditioner and battery
regulation .
♦ The electrically driven air conditioner compressor is not fitted
with an air conditioner compressor regulating valve - N280- .
♦ Prior to installation, check the air conditioner compressor and
bracket attachment points. The contact surfaces must be
clean and free of rust and grease. If this is not the case, treat
the contact surfaces accordingly with the contact surface
cleaning set - VAS 6410- ⇒ Electrical system; General infor‐
mation; Rep. gr. 97 ; Repairing wiring harnesses and con‐
nectors .

Note
♦ If the control unit for air conditioning compressor - J842- is

defective, the amount of refrigerant oil in the new air condi‐
tioner compressor must be adjusted. The refrigerant circuit
does not have to be flushed with R134a.
♦ The control unit for air conditioning compressor - J842- and
the electrical air conditioner compressor - V470- form one
component and cannot be separated at present.
♦ The electrically driven air conditioner compressor is not fitted
with -N280- . The output of the air conditioner compressor is
regulated externally by way of the air conditioner compressor
speed ⇒ Current flow diagrams, Electrical fault finding and Fit‐
ting locations and ⇒ Vehicle diagnostic tester, “Guided Fault
Finding” function for air conditioner and battery regulation .
♦ At present, the electrically driven air conditioner compressor
operates on the principle of a scroll-type supercharger (similar
to the "G-Lader" supercharger).
♦ The air conditioner compressor contains refrigerant oil which
mixes with refrigerant R134a at all temperatures.
♦ The type plate indicates the refrigerant for which the air con‐
ditioner compressor is designed.
♦ The integrated electronics regulate the output of the air con‐
ditioner compressor (and thus the pressure on the low-pres‐
sure side) within the specified range (control characteristic) by
way of the speed.
♦ The engine should only be started after the refrigerant circuit
has been assembled completely.
♦ The air conditioner compressor is fitted with a secured oil sup‐
ply to prevent damage if the refrigerant circuit is empty. This
means that approx. 40 to 50 cm3 of refrigerant oil remains in
the air conditioner compressor.
♦ Like the mechanically driven air conditioner compressor, the
electrically driven air conditioner compressor has a pressure
relief valve.
♦ On vehicles with battery cooling, hybrid operation is only pos‐
sible with the air conditioner charged and with no air condi‐
tioner faults stored ⇒ Vehicle diagnostic tester, “Guided Fault
♦ After installing the electrically driven air conditioner compres‐
sor and then charging the refrigerant circuit, first start up the
compressor via the “Compressor run-in” function of the basic
setting routine. Otherwise, the air conditioner compressor may
be damaged if refrigerant oil has accumulated in the compres‐
sion chamber of the air conditioner compressor due to inap‐
propriate storage prior to installation ⇒ Vehicle diagnostic
tester in “Guided Fault Finding” mode for air conditioner and
battery regulation .
♦ An electrically driven air conditioner compressor may only be
activated when the refrigerant circuit is charged. Running the
air conditioner compressor with the refrigerant circuit empty
could lead to compressor damage ⇒ Vehicle diagnostic tester
(“Guided Fault Finding” mode for air conditioner and battery
regulation) .

3.2.3 Condenser
The condenser transfers heat from the compressed refrigerant
gas to the surrounding air.
When this happens, the refrigerant gas condenses to liquid.
Note
♦ Depending on the design of the refrigerant circuit, the receiver

may be attached to the condenser or integrated in the con‐
denser ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit (vehicle-specific Workshop Manual) and ⇒ Electronic
parts catalogue .
♦ There are different versions of the condenser; from the outside
these versions can only be identified by their part number.
Version -1- of the condenser is split into two sections (“two-
pass condenser”). Version -2- of the condenser is split into four
sections (“four-pass condenser”).
♦ This illustration shows a condenser with the receiver -C- at‐
tached.
♦ The gaseous refrigerant enters the condenser at connection
-A-; the refrigerant is then cooled down in the condenser and
turns into liquid.
♦ The liquid refrigerant accumulates in receiver -C- (with dryer)
and flows through the bottom cooling section to connection
-B-.
♦ The refrigerant capacity in a refrigerant circuit may differ de‐
pending on the design of the condenser (internal volume, flow,
etc.). Therefore always pay attention to the correct version and
allocation of the condenser ⇒ page 276 and ⇒ Electronic
parts catalogue .
3.2.4 Evaporator
Evaporators come in different versions. Depending on the layout
and function, the thermal energy required to evaporate the refrig‐
erant is taken from the air flowing through the evaporator (e.g. in
the case of the evaporator in the air conditioning unit or in the
battery cooling module) or the coolant flowing through the evap‐
orator (e.g. in the case of the heat exchanger for high-voltage
battery) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit (vehicle-specific Workshop Manual).
Note
Two evaporator versions are described below.

Evaporator in the air conditioning unit (or in the battery cooling

module)
The liquid refrigerant evaporates in the tubes of the evaporator.
The heat required for this is extracted from the air flowing past the
evaporator fins. The air cools down. The refrigerant evaporates
and is extracted from the air conditioner compressor with the ab‐
sorbed heat.
A defined quantity of refrigerant is supplied to the evaporator by
way of a restrictor or expansion valve. In systems with an expan‐
sion valve, the flow rate is regulated so that only gaseous refrig‐
erant emerges at the evaporator outlet.
Evaporator/heat exchanger for high-voltage battery (chiller)
The liquid refrigerant evaporates in the evaporator (heat ex‐

changer). The heat required for this is extracted from the coolant
flowing through the evaporator. The coolant cools off, and the re‐
frigerant evaporates and is drawn in by the air conditioner com‐
pressor with the absorbed heat.
A specified quantity of refrigerant is supplied to the evaporator via
a restrictor (or an expansion valve) and a shut-off valve. The flow
rate of the refrigerant (or coolant) is regulated so that the refrig‐
erant emerging from the evaporator outlet is in gaseous form only
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (ve‐
hicle-specific Workshop Manual).
3.2.5 Heat exchanger for heat pump opera‐

tion
The refrigerant (gaseous or vaporous) compressed by the air
conditioner compressor is liquefied in the heat exchanger -A-; the
released heat is transferred to the coolant flowing through ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-
specific Workshop Manual).
3.2.6 Fluid collector

In certain operating modes (e.g. in heat pump mode), the receiver
(e.g. on the condenser). is not incorporated in the refrigerant cir‐
cuit. The fluid collector -B- collects the refrigerant, stores a certain
amount of it (if not required) and then transfers it as a continuous
flow to the expansion valve (in front of the evaporator in the heater
and air conditioning unit) or to the heat exchanger in the high-
voltage system's coolant circuit ⇒ Heating, air conditioning; Rep.
gr. 87 ; Refrigerant circuit (vehicle-specific Workshop Manual).

3.2.7 Reservoir
The reservoir collects the vapour and gas mixture coming from
the evaporator to ensure that the air conditioner compressor only
receives gaseous refrigerant. The vapour turns into gaseous re‐
frigerant.
Refrigerant oil entrained in the circuit does not remain in the res‐
ervoir as there is an oil extraction hole.
Any moisture which enters the refrigerant circuit during assembly
is trapped by a filter (desiccant bag) in the reservoir.
Gaseous refrigerant with oil is drawn in by the air conditioner
compressor.
Note
♦ Renew reservoir if refrigerant circuit has been open for a rel‐

atively long period and moisture has entered, or if renewal is
stipulated due to a specific complaint ⇒ page 258 .
♦ Do not remove sealing plugs -A- and -B- until immediately prior
to installation.
♦ If a reservoir is not sealed, the desiccant bag soon becomes
saturated with moisture and can no longer be used.
♦ When installing, observe arrow indicating direction of flow (if
applicable).
3.2.8 Restrictor
Restrictor upstream of evaporator
The restrictor creates a constriction. The restriction restricts the
flow, thus separating the refrigerant circuit into high and low-pres‐
sure sides. Upstream of the restrictor, the refrigerant is warm due
to the high pressure. Downstream of the restrictor, the refrigerant
is cold due to the low pressure. A strainer is fitted upstream of the
constriction to trap dirt. The strainer downstream of the constric‐
tion is designed to atomise the refrigerant before it enters the
evaporator.
Note
♦ Arrow -A- on restrictor faces evaporator.

♦ Always renew after opening circuit.
♦ There are different versions; observe the notes in the service
information media available ⇒ Heating, air conditioning; Rep.
gr. 87 ; Refrigerant circuit (vehicle-specific Workshop Manual)
and ⇒ Electronic parts catalogue .
Restrictor upstream of heat exchanger for high-voltage battery

(chiller)

The restrictor creates a restriction, which restricts the flow, thus

separating the refrigerant circuit into high and low-pressure sides.
Upstream of the restrictor, the refrigerant is warm due to the high
pressure. Downstream of the restrictor, the refrigerant is cold due
to the low pressure.
Note
♦ The illustration shows a refrigerant line -A- with a permanently

installed restrictor -B- (without strainer).
♦ The diameter of the restrictor hole -B- is approx. 0.7 mm. De‐
pending on the version of the refrigerant line, the restrictor is
either only inserted or fixed in position in the refrigerant line. If
it is inserted, there may be a strainer for separating float ele‐
ments, which may block off the restrictor hole.
♦ Prior to installation, check for dirt, and clean or renew the
component as necessary.
♦ There are different versions; observe the notes in the service
information media available ⇒ Heating, air conditioning; Rep.

3.2.9 Receiver
The receiver collects the droplets of liquid and conveys them in a
continuous stream to the expansion valve. Any moisture ingress‐
ing into the refrigerant circuit during assembly is collected by a
dryer in the receiver.
Note
♦ Renew receiver if refrigerant circuit has been open for a rela‐

tively long period and moisture has entered, or if renewal is
stipulated due to a specific complaint ⇒ page 258 .
♦ Do not remove sealing plugs until just before installation.
♦ If the receiver is not sealed, the desiccant bag soon becomes
saturated with moisture and thus unusable.
♦ When installing, observe arrow indicating direction of flow (if
applicable).
♦ Depending on the design of the refrigerant circuit, the receiver
may also be attached to the condenser or integrated in the
condenser ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
erant circuit (vehicle-specific Workshop Manual) and ⇒ Elec‐
tronic parts catalogue .
♦ The procedure for dealing with problems differs depending on
the version of the receiver / desiccant cartridge. If, for example,
the receiver is attached to the condenser, it can be renewed
together with the desiccant cartridge. If, for example, the re‐
ceiver is integrated into the condenser, it is usually possible to
renew the desiccant cartridge and any additional filter element
separately. If the receiver is integrated into the condenser and
it is not possible to renew the receiver/desiccant cartridge
separately, it may be necessary to renew the entire condenser
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
(vehicle-specific Workshop Manual) and ⇒ Electronic parts
catalogue .
♦ Depending on the design of the refrigerant circuit, the desic‐
cant bag (desiccant cartridge) may also be installed in the
condenser ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
erant circuit (vehicle-specific Workshop Manual) and ⇒ Elec‐

3.2.10 Expansion valve

The expansion valve atomises the refrigerant flowing in and con‐
trols the flow rate according to the heat transfer so that it does not
vaporise before reaching the evaporator outlet.
Note
♦ Pay attention to the correct part number on renewing the ex‐

pansion valve. ⇒ Electronic parts catalogue.
♦ Different characteristic curves are matched to the relevant cir‐
cuit ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
parts catalogue .
3.2.11 Expansion valve with shut-off valve
Note
There are different shut-off valve versions with different functions

and designations. On the Audi Q5 hybrid, for example, the refrig‐
erant shut-off valve 2 for hybrid battery - N517- (as illustrated
below) is installed in the battery cooling module ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific
Workshop Manual).

♦ The expansion valve -A- with -N517- -B- atomises the refrig‐
erant flowing through and regulates the flow of refrigerant to
the evaporator in the battery cooling module of the hybrid bat‐
tery unit - AX1- so that - depending on the heat transferred -
the vapour only turns into gas at the outlet of the evaporator.
♦ When -N517- -B- is actuated by the electronic system, it is
open and allows refrigerant to flow through the expansion
valve -A- to the evaporator in the battery cooling module.
♦ The expansion valve -A- with -N517- -B- is installed on vehi‐
cles with battery cooling module. It is actuated in air condi‐
tioning mode if the hybrid battery unit - AX1- needs to be
cooled.
♦ If -N517- -B- is actuated by the electronic system (e.g. by the
battery regulation control unit - J840- ), it is opened and allows
refrigerant to flow to the evaporator in the battery cooling mod‐
ule according to its control characteristics.
♦ The solenoid -N517- -B- (fitted at expansion valve -A-) is ac‐
tivated e.g. by the battery regulation control unit - J840- ⇒ Cur‐
rent flow diagrams, Electrical fault finding and Fitting locations
and ⇒ Vehicle diagnostic tester (“Guided Fault Finding” for air
conditioner and battery regulation) .
♦ If, on a vehicle with two evaporators (one each in the air con‐
ditioning unit and battery cooling module as e.g. on the Audi
Q5 Hybrid), the measured temperature corresponds to or is
below the specified value at one evaporator but the required
specified value is not attained at the other evaporator, the sys‐
tem is controlled as follows: the battery regulation control unit
- J840- actuates the electric air conditioner compressor at a
higher speed via the power and control electronics for electric
drive - JX1- and the control unit for air conditioning compressor
- J842- . This causes the cooling output of the air conditioner
to increase and the pressure on the low-pressure side and the
evaporator temperature to drop. If the required temperature
value is then not reached at one evaporator, -J840- activates
the refrigerant shut-off valve 1 for hybrid battery - N516- or the
refrigerant shut-off valve 2 for hybrid battery - N517- so that
refrigerant no longer flows through the evaporator which is too
cold ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
mode for air conditioner .
3.2.12 Refrigerant shut-off valves
Note
♦ There are different shut-off valve versions with different func‐

tions and designations. For example, the refrigerant shut-off
valve 1 for hybrid battery - N516- (as illustrated below) is in‐
stalled in the Audi Q5 hybrid ⇒ Heating, air conditioning; Rep.
gr. 87 ; Refrigerant circuit (vehicle-specific Workshop Man‐
ual).
♦ Different designations, depending on the function and vehicle
(vehicle-specific Workshop Manual).
Shut-off valve with two switch statuses (open and closed)

♦ Refrigerant shut-off valve 1 for hybrid battery - N516- (e.g. on
the Audi Q5 hybrid)
♦ Refrigerant shut-off valve for heater and air conditioner unit -
N541- (e.g. on the Audi A3 e-tron)

♦ Refrigerant shut-off valve for high-voltage battery heat ex‐

changer - N542- (e.g. on the Audi A3 e-tron)
♦ Refrigerant shut-off valve - V424- (e.g. on the Audi Q7 e-tron)
♦ When the shut-off valve -A- is not actuated by the electronic
system, it is open and allows refrigerant to flow to the evapo‐
rator in the air conditioning unit.
♦ The shut-off valve -A- is e.g. installed on vehicles with battery
cooling module. It is actuated in hybrid mode if the air condi‐
tioner is not set to cooling mode for the passenger compart‐
ment, but the hybrid battery unit - AX1- needs to be cooled.
♦ Observe the arrow -B- on the shut-off valve -A-; it shows the
flow direction of the refrigerant (from condenser to evaporator
in the air conditioning unit).
♦ The solenoid -C- (fitted at the shut-off valve) is actuated e.g.
by the battery regulation control unit - J840- ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations and ⇒
Vehicle diagnostic tester in “Guided Fault Finding” mode for
air conditioner and battery regulation .
♦ If e.g. on a vehicle with two evaporators (one each in the air
conditioning unit and battery cooling module as e.g. on the
Audi Q5 Hybrid), the measured temperature corresponds to
or is below the specified value at one evaporator but the re‐
quired specified value is not attained at the other evaporator,
the system is controlled as follows: the relevant control unit
(e.g. the control unit for battery regulation - J840- on the Audi
Q5 Hybrid) actuates the electric air conditioner compressor at
a higher speed via the control unit for air conditioning com‐
pressor - J842- . This causes the cooling output of the air
conditioner to increase and the pressure on the low-pressure
side and the evaporator temperature to drop. If the required
temperature value is then not reached at one evaporator, the
responsible control unit (e.g. -J840- on the Q5 hybrid) acti‐
vates the refrigerant shut-off valve 1 for hybrid battery - N516-
or the refrigerant shut-off valve 2 for hybrid battery - N517- so
that refrigerant no longer flows through the evaporator which
is too cold ⇒ Vehicle diagnostic tester in “Guided Fault Find‐
ing” mode for air conditioner and ⇒ Heating, air conditioning;
Rep. gr. 87 ; Refrigerant circuit (vehicle-specific Workshop
Manual).
Shut-off valves controlled via characteristic curves
♦ Refrigerant shut-off valve 2 - N640- to refrigerant shut-off valve
5 - N643- (e.g. on the Audi Q7 e-tron)
♦ Refrigerant expansion valve 1 - N636- (e.g. on the Audi Q7 e-
tron)

♦ Shut-off valve -A- is activated using a stepper motor -B- of the

corresponding control unit via characteristic curves (open or
closed).
♦ If the shut-off valve is operating as a control valve (e.g. as the
refrigerant expansion valve 1 - N636- on the Audi Q7) it is only
opened as far as necessary until the specified temperature for
the heat exchanger is reached ⇒ Heating, air conditioning;
Manual).
♦ The shut-off valves activated by stepper motors have no speci‐
fied rest position. They must therefore be moved to a specific
position (open or closed) before any work is performed on the
refrigerant circuit ⇒ Heating, air conditioning; Rep. gr. 87 ;
♦ Depending on the layout of the refrigerant circuit, several shut-
off valves may be combined in one valve block (e.g. on the
Audi Q7 e-tron) ⇒ Heating, air conditioning; Rep. gr. 87 ;
♦ The stepper motor is adapted and activated via data lines (LIN
bus) by the corresponding control unit according to their fitting
location ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit (vehicle-specific Workshop Manual) and ⇒ Vehicle di‐
agnostic tester (“Guided Fault Finding”).
3.2.13 Refrigerant line with internal heat ex‐

changer
In this refrigerant line, the hot refrigerant (liquid) flowing through
the high-pressure side gives off energy to the cold refrigerant
(gaseous or vaporous) flowing through the low-pressure side,
thus enhancing the efficiency of the air conditioner.
Note
This illustration shows a refrigerant line with internal heat ex‐

changer as fitted e.g. on the Audi A4 2008 > and the Audi A5
Coupé 2008 > ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
erant circuit (vehicle-specific Workshop Manual).
A - Refrigerant line with internal heat exchanger

B - Passages in refrigerant line, in which hot liquid refrigerant
flows to evaporator (high-pressure side of refrigerant circuit)
C - Passage in refrigerant line, in which cold gaseous or vaporous
refrigerant flows to air conditioner compressor (low-pressure side
of refrigerant circuit)
3.2.14 Quick-release couplings on refrigerant

line
WARNING
Only release and open the quick-release couplings after com‐

pletely discharging the refrigerant circuit.

Note
♦ This illustration shows the quick-release couplings with a re‐

frigerant line with internal heat exchanger as fitted e.g. on the
Audi A4 2008 > and the Audi A5 Coupé 2008 > ⇒ Heating, air
Workshop Manual).
♦ Removal of the refrigerant line -D- involves opening the re‐
taining ring -A- with the refrigerant line release tool -T40149/-
for example ⇒ Heating, air conditioning; Rep. gr. 87 ;
♦ Following removal of the applicable refrigerant line, renew the
quick-release couplings -B- and -G- together with the corre‐
sponding support ring -E- or -H- and the corresponding O-ring
-F- or -J- ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
parts catalogue .
A - Retaining ring (in quick-release coupling, high-pressure side)

B - Quick-release coupling with retaining ring (high-pressure side)
C - Refrigerant line with internal heat exchanger
D - Refrigerant line (high-pressure side)
E - Support ring (high-pressure side)
F - O-ring (“high-pressure side”)
G - Quick-release coupling with retaining ring (low-pressure side)
H - Support ring (low-pressure side)
J - O-ring (“low-pressure side”)
Note
♦ There are different versions of the quick-release couplings

-A- and -D-. With both versions of these quick-release cou‐
plings, the refrigerant lines -C- can be released in the identical
manner using the refrigerant line release tool -T40149/1- for
example and removed.
♦ With the quick-release coupling -A- fitted at the start of pro‐
duction, the pins -B- become visible after fitting the refrigerant
line -C- if the locked refrigerant line -C- is pulled in arrow di‐
rection.
♦ With the quick-release coupling -D- installed from model year
2010 onwards (gradual introduction), the refrigerant line -C- is
installed in the same way as with the quick-release coupling
-A-. If, on this version, the refrigerant line -C- is pulled in the
direction of the arrow after it is assembled, the snap ring -E-
emerges from the quick-release coupling -D-, showing that the
retaining ring -F- is completely locked onto the refrigerant line
-C-. The snap ring -E- is then to be detached from the refrig‐
erant line -C-.

3.2.15 O-rings
These rings seal the joints between the individual components of
the refrigerant circuit.
Only O-rings resistant to R134a refrigerant and the related refrig‐
erant oils are to be used. This is guaranteed if genuine replace‐
ment parts are used.
O-rings:
– Use only once.
– Observe correct diameters -a- and -b-.
– Before installing, lubricate lightly with refrigerant oil ⇒ Heating,
air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-spe‐
cific Workshop Manual) and ⇒ Electronic parts catalogue .
Note
The colour coding of O-rings for R134a refrigerant circuits has

been discontinued. Black and coloured O-rings are used ⇒ Elec‐
tronics parts catalogue and ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit (vehicle-specific Workshop Manual).
3.2.16 Pipes and hoses of refrigerant circuit

The mixture of refrigerant oil and refrigerant R134a corrodes cer‐
tain metals (e.g. copper) and alloys and dissolves certain hose
materials. Therefore, always use genuine replacement parts.
The pipes and hoses are joined with bolted connections or special
connectors.
Note
Observe specified torques for bolted joints and use the specified
release tools for connectors.
3.2.17 High-pressure safety valve

The high-pressure safety valve is attached to the air conditioner
compressor or the receiver.
The valve opens at a pressure of approx. 38 bar and closes again
when the pressure has dropped (approx. 30 bar).
Not all the refrigerant escapes.

Note
♦ Depending on the version, a transparent plastic disc -B- may

be attached to the high-pressure safety valve -A-. The disc
breaks off as soon as the valve is actuated.
♦ Depending on the version of the high-pressure safety valve
-A-, there may also be a cover -C- on the high-pressure safety
valve -A-. Should the pressure in the refrigerant circuit ever
exceed the opening pressure of the high-pressure safety valve
-A-, causing the high-pressure safety valve to open, the re‐
frigerant does not emerge in one direction but is distributed
through the openings -D- under the cover -C-.
♦ Should it be necessary to renew a high-pressure safety valve
-A-, please observe the correct tightening torque when instal‐
ling (dependent on air conditioner compressor manufacturer
and version). On air conditioner compressors manufactured
by Denso (or Nippondenso), Sanden or Zexel/Valeo, an O-ring
is fitted (tightening torque: currently 10 Nm for Denso and
Zexel/Valeo; 15 Nm for Sanden). On Delphi air conditioner
compressors, a seal is fitted (tightening torque: currently 15
Nm).
♦ Renew seal/O-ring ⇒ Electronic parts catalogue .
♦ If the seal/O-ring fitted at the high-pressure safety valve can‐
not be supplied as a replacement part, the removed compo‐
nent can be re-installed as an exception; it must be checked
for damage before being re-installed. If the removed seal/O-
ring is damaged or deformed, it must be replaced by a com‐
mercially available component ⇒ Electronic parts catalogue .
♦ After charging the refrigerant circuit, check the installed high-
pressure safety valve for leaks, e.g. with an electronic leak
detector.
3.2.18 Non-return valves

Non-return valves separate the refrigerant circuit into different
sections.
Note
♦ The non-return valve -3- in the illustration is installed e.g. on

the Audi Q7 e-tron.
♦ Non-return valves in the refrigerant circuit have a specific
holding pressure (approx. 0.1 bar or 100 mbar) in the forward
direction. All electrically activated valves must therefore be
open so that the refrigerant circuit can be evacuated fully (re‐
sidual pressure less than 5 mbar).
♦ Depending on the version, there may be a sticker indicating
the direction of flow.

3.3 Design of refrigerant circuit

⇒ “3.3.1 Refrigerant circuit with expansion valve and evaporator”,
page 39
⇒ “3.3.2 Refrigerant circuit with restrictor and reservoir”,
page 39
⇒ “3.4 Refrigerant circuit with electrically driven air conditioner
compressor”, page 40
3.3.1 Refrigerant circuit with expansion valve

and evaporator
The following illustration only shows the general layout of a typical
refrigerant circuit; refer to the vehicle-specific Workshop Manual
for the layout of that vehicle's refrigerant circuit ⇒ Heating, air
Workshop Manual).
1- Evaporator
2- Expansion valve
3- Valve for extraction, charging and measurement
4- Sight glass (not fitted with R134a circuits)
5- Receiver with dryer
6- Condenser
7- Air conditioner compressor
Note
Arrows show direction of refrigerant flow.
3.3.2 Refrigerant circuit with restrictor and

reservoir
The following illustration only shows the general layout of a typical
refrigerant circuit; refer to the vehicle-specific Workshop Manual
for the layout of that vehicle's refrigerant circuit ⇒ Heating, air
Workshop Manual).
1- Air conditioner compressor
2- Condenser
3- Restrictor
4- Evaporator
5- Reservoir
Note

3.4 Refrigerant circuit with electrically driven

air conditioner compressor
Note
The following illustration shows the refrigerant circuit fitted in the

Audi Q5 hybrid as an example; refer to the vehicle-specific Work‐
shop Manual for the layout of that vehicle's refrigerant circuit ⇒
1 - Electrically driven air condi‐

tioner compressor
❑ With control unit for air
conditioning compres‐
sor - J842- and electrical
air conditioner compres‐
sor - V470-
2 - Condenser
❑ With receiver and desic‐
cant cartridge
3 - Service connection (high-
pressure side)
4 - Refrigerant shut-off valve 1
for hybrid battery - N516-
❑ Only on vehicles with
battery cooling module
for hybrid battery unit -
AX1-
Note
-N516- is activated, for example, if

the battery needs to be cooled but
the air conditioner is not set to cool‐
ing mode for the passenger com‐
partment (valve open when not
activated).
5 - Expansion valve
❑ At evaporator in air con‐
ditioning unit
6 - Evaporator
❑ Evaporator in air condi‐
tioning unit
7 - Expansion valve with refrig‐
erant shut-off valve 2 for hybrid battery - N517-
❑ At evaporator in battery cooling module
❑ Only on vehicles with battery cooling module for hybrid battery unit - AX1-
Note
-N517- is activated if battery needs

to be cooled (closed when not acti‐
vated).

8 - Evaporator
❑ Evaporator in battery cooling module
❑ Only on vehicles with battery cooling module for hybrid battery unit - AX1-
9 - Service connection (low-pressure side)
3.5 Connections for quick-release coupling

in refrigerant circuit
• Only use valves and connections that are resistant to R134a
refrigerant and related refrigerant oils.
• There are different connections (outer diameter) for high and
low-pressure sides.
• Discharge refrigerant circuit before removing valves or valve
cores.
• Always screw on sealing caps.
Layout in vehicle ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐
frigerant circuit (vehicle-specific Workshop Manual)
WARNING
Risk of injury (frostbite).

Refrigerant may escape if the refrigerant circuit has not been
discharged.
Extract refrigerant before opening refrigerant circuit. Renewed
evaporation may create pressure in refrigerant circuit if refrig‐
erant circuit is not opened within 10 minutes following extrac‐
tion. Extract refrigerant again.

⇒ “3.5.1 Connections with Schrader valve (needle valve)”,

page 42
⇒ “3.5.2 Connections with primary sealing valve (ball valve)”,
page 42
⇒ “3.5.3 Differences in service connections depending on refrig‐
erant (R134a or R1234yf)”, page 45
3.5.1 Connections with Schrader valve (nee‐

dle valve)
♦ -A- Service connection (soldered in)
♦ -B- Valve core (designation: Schrader valve or needle valve)
♦ -C- O-ring (for valve)
♦ -D- Sealing cap with seal
Note
♦ After connecting, carefully screw handwheel of service cou‐

pling into quick-release coupling adapter only to the extent
required to reliably open valve in service connection (observe
pressure gauge; do not open valve too far).
♦ When removing and installing valve core -B- with refrigerant
circuit discharged, use e.g. adapter from socket - T10364- .
♦ Take care when tightening valve core -B- (low torque).
♦ There are different versions of these valves; therefore tight‐
ening torques vary. For a valve core -B- with a VG5 thread
(5.2 x 0.7 mm, tyre valve) the tightening torque is 0.4 Nm
+/- 0.1 Nm; for a valve core with an M6 x 0.75 mm thread, the
tightening torque is 0.9 Nm +/- 0.1 Nm, and for a valve core
with an M8 x 1.0 mm thread, the tightening torque is
2.0 Nm +/- 0.2 Nm.
♦ There are different versions of these valves, valve cores and
corresponding sealing caps. Note the correct version of the
valve core and correct assignment of the sealing caps ⇒ Elec‐
3.5.2 Connections with primary sealing valve

(ball valve)
WARNING
Before unscrewing the connection, connect the air conditioner

service station and extract refrigerant. The refrigerant circuit
must be empty; danger of injury.

Connection with high-pressure valve

1- Connection with internal thread (soldered in)
2- O-ring (version and identification: black or coloured ⇒ Elec‐
tronic parts catalogue )
3- Valve with external thread and groove for O-ring (designa‐
tion: ball valve)
4- Seal for cap
5- Cap
Depending on the vehicle, high pressure may not be available at
the service connection on the high-pressure side in all air condi‐
tioner operating modes (e.g. on the Audi Q7 e-tron). The senders
installed in the refrigerant circuit must therefore be used to check
that the air conditioner in these vehicles is functioning properly ⇒
specific Workshop Manual) and ⇒ Vehicle diagnostic tester in
Note
♦ After connecting, carefully screw handwheel of service cou‐

pling into quick-release coupling adapter only to the extent
required to reliably open valve in service connection (observe
pressure gauge; do not open valve too far).
♦ When removing and installing valve -3- with refrigerant circuit
discharged, use e.g. an adapter from socket - T10364- .
♦ There are different versions of these valves (with internal or
external thread); therefore the tightening torques may vary.
For the valves -3- currently in use (external thread M12 x 1.5
mm) the tightening torque is 9 Nm +/- 1 Nm.
♦ There are different versions of these valves and the corre‐
sponding sealing caps. Note the correct version of the valve
and correct assignment of the sealing cap ⇒ Electronic parts
catalogue .

Connection with low-pressure valve

1- Connection with external thread and groove for O-ring (sol‐
dered in)
2- O-ring (version and identification: black or coloured ⇒ Elec‐
tronic parts catalogue )
3- Valve with internal thread
4- Seal for cap
5- Cap
Note
♦ Screw handwheel of service coupling into quick-release cou‐

pling adapter carefully and only to the extent required to
reliably open valve in service connection (observe pressure
gauge; do not open valve too far).
♦ When removing and installing valve -3- with refrigerant circuit
discharged, use e.g. an adapter from socket - T10364- .
♦ There are different versions of these valves (with internal or
external thread); therefore the tightening torques may vary.
For the valves -3- currently in use (internal thread
M10 x 1.25 mm) the tightening torque is 9 Nm +/- 1 Nm.
♦ There are different versions of these valves and the corre‐
sponding sealing caps. Note the correct version of the valve
and correct assignment of the sealing cap ⇒ Electronic parts
catalogue .

3.5.3 Differences in service connections de‐

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

corresponding refrigerant (R134a and/or R1234yf) and related
refrigerant oils ⇒ Electronic parts catalogue .
♦ The service connections for the refrigerant circuits are de‐
signed such that only the specified service couplings for the
specified refrigerant (R134a or R1234yf) can be connected.
♦ These illustrations show service connections in which a
Schrader valve (needle valve or push pin) is installed. How‐
ever, depending on the vehicle version or the type of refriger‐
ant etc., service connections with a primary sealing valve (ball
valve) may also be installed (different technology)
⇒ “3.5.2 Connections with primary sealing valve (ball valve)”,
page 42 .
♦ Layout in vehicle and on refrigerant circuit ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific
Workshop Manual).
♦ There are different connections (outer diameter) for high and
low-pressure sides.
♦ Discharge refrigerant circuit before removing valves or valve
cores
⇒ “5.3.3 Discharging refrigerant circuit with air conditioner
service station”, page 73 .
♦ Removing and installing valve from service connection (low
and high-pressure sides)
⇒ “3.5.1 Connections with Schrader valve (needle valve)”,
page 42 .
♦ Always screw on sealing caps with seal.

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

service station and extract refrigerant. Refrigerant circuit must
be empty; danger of injury
⇒ “5.3.3 Discharging refrigerant circuit with air conditioner
service station”, page 73 .
♦ Cap for service connection (high-pressure side) -A- with seal

-G-
♦ Valve core on high-pressure side (version: Schrader valve or
needle valve) -B-
♦ Service connection (high-pressure side) -C-
♦ Cap for service connection (low-pressure side) -D- with seal
-G-
♦ Valve core on low-pressure side (version: Schrader valve or
needle valve) -E-
♦ Service connection (low-pressure side) -F-
Note
♦ Service connections -C, F- for refrigerant R134a and R1234yf

are available in different versions (depending on manufactur‐
er), with different sealing caps -A, D- and valves -B, E-. Ensure
correct assignment ⇒ Electronic parts catalogue .
♦ Sealing caps -A, D- for the service connections on the R134a
refrigerant circuit are currently black. The sealing caps for the
service connections on the R1234yf refrigerant circuit are cur‐
rently grey. The refrigerant type (e.g. “R1234yf”) may also be
printed on the sealing caps.
♦ After connecting, carefully screw the handwheel of the service
coupling into the quick-release coupling adapter only to the
extent required to reliably open the valve -B, E- in the service
connection (observe the pressure gauge; do not open the
valve -B, E- too far).
♦ The service connections -C, F- for R134a and R134yf refrig‐
erant circuits are designed such that only the service couplings
specified for the corresponding refrigerant can be connected
(different dimensions ⇒ page 47 ).
♦ Service connections -C, F-, for example, are soldered into a
refrigerant line and therefore cannot be renewed separately.
♦ To remove and install the valves -B, E- (with the refrigerant
circuit drained), make use of an adapter from the socket -
T10364- for example.
♦ Take care when tightening the valves -B, E- (low torque).
♦ These valves are available in different versions with differing
tightening torques. Tightening torque for valve core -C-with a
VG5 thread (5.2 x 0.7 mm tyre valve): 0.4 Nm. +- 0.1 Nm;
tightening torque for valve core with an M6 x 0.75 mm thread:
0.9 Nm +- 0.1 Nm; tightening torque for valve core with an M8
x 1.0 mm: 2.0 Nm +- 0.2 Nm.
♦ There are different versions of valve caps -A, D-; therefore
tightening torques vary. Tightening torque for valve cap with
M8 x 1 mm or M10 x 1 mm thread: 0.4 Nm +- 0.1 Nm.

Dimensions of service connections
♦ Valve core -A- (different versions; refer to ⇒ Electronic parts

catalogue )
♦ Service connection -B- (different versions on high-pressure
and low-pressure side depending on refrigerant)
Dimensions of serv‐ Service connec‐ Service connection
ice connections -B- tion (refrigerant (refrigerant
R134a) R1234yf)
High- Low- High- Low-
pressure pres‐ pressure pressure
side sure side side
side
Outer diameter -D1- 16.0 mm 13.0 17.0 mm 14.0 mm
mm
Outer diameter -D2- 14.0 mm 11.0 13.0 mm 12.0 mm
mm
Offset -L1- 4.6 mm 6.15 9.0 mm 4.75 mm
mm
Offset -L2- 8.16 mm 9.16 12.5 mm 7.2 mm
mm
Installation position of 6.1 - 7.1 6.1 - 7.1 8.3 - 9.3 8.3 - 9.3
valve (not actuated) mm mm mm mm
-C-
3.6 Switches and senders in refrigerant cir‐

cuit and related connections
Note
Refer to vehicle-specific refrigerant circuit for switching pres‐

sures, removing and installing switches and location/design of
switches ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant

⇒ “3.6.1 High-pressure switch for air conditioning system F23 ”,

page 48
⇒ “3.6.2 High-pressure switch for magnetic clutch F118 ”,
page 48
⇒ “3.6.3 Low-pressure switch for air conditioning system F73 ”,
page 49
⇒ “3.6.5 Air conditioning system pressure switch F129 ”,
page 49
⇒ “3.6.6 High-pressure sender G65 and pressure sender for re‐
frigerant circuit G805 ”, page 50
⇒ “3.6.7 Refrigerant pressure and temperature sender”,
page 51
⇒ “3.6.4 Connections with valve for refrigerant circuit switches”,
page 49
⇒ “3.6.8 Air conditioner compressor regulating valve N280 ”, page
54
⇒ “3.6.9 Air conditioner compressor speed sender G111 ”, page
54
⇒ “3.6.10 Refrigerant temperature sender G454 ”, page 55
3.6.1 High-pressure switch for air conditioning

system - F23-
Function:
Switches the radiator fan up to the next speed setting in the event
of a pressure increase in the refrigerant circuit (approx. 16 bar).
3.6.2 High-pressure switch for magnetic

clutch - F118-
Function:
Switches off the air conditioner compressor in the event of excess
pressure in the refrigerant circuit (approx. 32 bar).

3.6.3 Low-pressure switch for air conditioning

system - F73-
Function:
Switches off the air conditioner compressor in the event of a pres‐
sure drop in the refrigerant circuit (approx. 2 bar).
3.6.4 Connections with valve for refrigerant

circuit switches
• Different threads for switches on high- and low pressure sides.
• Only valves and O-rings resistant to R134a refrigerant and the
related refrigerant oils are to be used.
A - Connection (soldered in)
B - O-ring
C - Valve (with O-ring)
Note
When removing and installing the valve core -C- with refrigerant
circuit discharged, use e.g. adapter from socket - T10364- (tight‐
ening torque ⇒ page 42 ).
3.6.5 Air conditioning system pressure switch

- F129-
This pressure switch has 3 functions:
1. Switches the radiator fan up to the next speed setting in the
event of a pressure increase (approx. 16 bar) in the refrigerant
circuit.
2. Switches off the air conditioner in the event of excessive pres‐
sure (approx. 32 bar) caused, for example, by inadequate engine
cooling.
3. Switches off the air conditioner in the event of insufficient pres‐
sure (approx. 2 bar) caused, for example, by a loss of refrigerant.
Note
The air conditioning system pressure switch - F129- replaces the

high-pressure switch for air conditioning system - F23- , the low-
pressure switch for air conditioning system - F73- and the high-
pressure switch for magnetic clutch - F118- .

3.6.6 High-pressure sender - G65- and pres‐

sure sender for refrigerant circuit -
G805-
♦ -G65- is installed instead of the air conditioning system pres‐
sure switch - F129- or the refrigerant pressure and tempera‐
ture sender - G395- .
♦ On some vehicles from a certain version and production date
onwards, -G805- replaces -G65- .
♦ When voltage is applied, one version of -G65- generates a
square-wave signal and the other generates a data telegram.
This signal changes with the pressure in the system. The other
version and -G805- exchange information with the corre‐
sponding control unit via the data bus (e.g. via the “LIN bus”)
when voltage is applied ⇒ Heating, air conditioning; Rep. gr.
♦ -G65- is installed e.g. in the Audi A3 2005> and the Audi Q3.
It transmits its measured values as square-wave signals to the
corresponding control unit (e.g. to the air conditioning system
control unit - J301- or the Climatronic control unit - J255- ). -
G65- is installed e.g. in the Audi Q7 2016>. It transmits its
measured values via a “LIN bus” ⇒ Vehicle diagnostic tester
(“Self-diagnosis” or “Guided Fault Finding” function for air con‐
ditioner) and ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations.
♦ -G805- is installed e.g. in the Audi A3 2013>. It exchanges
information with the corresponding control unit over a data bus
(e.g. in the Audi A3 with the air conditioning system control unit
- J301- or the Climatronic control unit - J255- ). ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations
♦ There are different versions of the refrigerant pressure and
temperature sender - G395- , the pressure sender for refrig‐
erant circuit - G805- and the high-pressure sender - G65- ;
depending on the version, they can currently only be distin‐
guished by the part number. Therefore pay attention to the
correct assignment when renewing the components (part
number ⇒ Electronic parts catalogue ). Reason: These two
senders emit different signals, and the relevant control units
can only evaluate the signal to which they have been matched
⇒ Vehicle diagnostic tester (“Self-diagnosis” or “Guided Fault
Finding” function for air conditioner), and ⇒ Heating, air con‐
Workshop Manual).
♦ -G65- and -G805- transmit only the measured value for the
pressure in the refrigerant circuit to the connected control unit.
-G395- transmits the measured value for the pressure in the
refrigerant circuit and the measured temperature to the con‐
nected control unit. Even if only the pressure signal is evalu‐
ated for a vehicle, a vehicle in which -G65- or -G805- is
intended to be installed must not be fitted with a -G395- ⇒
Electronic parts catalogue .
♦ The control units downstream (radiator fan control unit, engine
control unit, operating and display unit for front air conditioning
system - E87- or Climatronic control unit - J255- etc.) use this
signal to calculate the pressure in the refrigerant circuit; the
control units then actuate the radiator fans, motor and air con‐
ditioning system magnetic clutch - N25- accordingly or modify
the activation of the air conditioner compressor regulating
valve - N280- ⇒ Vehicle diagnostic tester (“Self-diagnosis” or
“Guided Fault Finding” function) and ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific Work‐
shop Manual).

3.6.7 Refrigerant pressure and temperature

sender
There are different versions of these senders with different func‐
tions and designations. For the exact designation, assignment
and information on the corresponding function, refer to ⇒ Heating,
air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific
Workshop Manual).
WARNING

discharged.
There are different versions of these senders (sender for a
connection on the refrigerant circuit with or without valve) ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (ve‐
♦ Before loosening the bolt securing the sender, check the
version of the sender ⇒ Heating, air conditioning; Rep.
gr. 87 ; Refrigerant circuit (vehicle-specific Workshop
Manual).
♦ With a sender for connecting to a refrigerant circuit without
valve. Extract the refrigerant before undoing the threaded
joint. Renewed evaporation may create pressure in the
refrigerant circuit if the sender is not removed within 10
minutes following extraction. Extract refrigerant again.
Senders for a connection with valve at refrigerant circuit
Note
♦ There are different versions of these senders with different

functions and designations. For example, the refrigerant pres‐
sure and temperature sender - G395- (as illustrated below) is
installed in the Audi A4, Audi Q5 and Audi Q5 hybrid ⇒ Heat‐
ing, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-

Possible designations for these senders

♦ Refrigerant pressure and temperature sender - G395- (e.g. on
the Audi Q5 hybrid)
♦ High-pressure sender - G65- (e.g. on the Audi A4)
♦ Pressure sender for refrigerant circuit - G805- (e.g. on the Audi
A3 e-tron)
Note
The pressure sender for refrigerant circuit - G805- is installed e.g.

instead of the high-pressure sender - G65- or the refrigerant pres‐
sure and temperature sender - G395- ⇒ Heating, air conditioning;
Rep. gr. 87 ; Refrigerant circuit (vehicle-specific Workshop Man‐
ual).
♦ There are different versions of the refrigerant pressure and

temperature sender - G395- , the pressure sender for refrig‐
erant circuit - G805- and the high-pressure sender - G65- ;
depending on the version, they can currently only be distin‐
guished by the part number. Therefore pay attention to the
correct assignment when renewing the components (part
number ⇒ Electronic parts catalogue ). Reason: These two
senders emit different signals, and the relevant control units
can only evaluate the signal to which they have been matched
⇒ Vehicle diagnostic tester (“Self-diagnosis” or “Guided Fault
Finding” function for air conditioner), and ⇒ Heating, air con‐
Workshop Manual).
♦ When voltage is applied, the refrigerant pressure and temper‐
ature sender - G395- (and the pressure sender for refrigerant
circuit - G805- ) exchange information with the corresponding
control unit via the data bus (e.g. “LIN bus”). The correspond‐
ing control unit uses this information to calculate the pressure
(and temperature) in the refrigerant circuit; any faults detected
are signalled to the control unit.
♦ -G395- transmits the measured value for the pressure in the
refrigerant circuit and the measured temperature to the con‐
nected control unit. -G805- transmits only the measured value
for the pressure in the refrigerant circuit to the connected con‐
trol unit. Even if only the pressure signal is evaluated on most
vehicles, a vehicle in which a -G395- is intended to be installed
must not be fitted with a -G805- ⇒ Electronic parts catalogue .
♦ The temperature measured by the refrigerant pressure and
temperature sender - G395- differs from the actual tempera‐
ture of the refrigerant in the refrigerant circuit due to the design
of -G395- and the fitting location. Therefore it is currently not
evaluated by all control units and used for air conditioner con‐
trol ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
♦ This information is used, for example, by the operating and
display unit ( Climatronic control unit - J255- ) or the onboard
supply control unit - J519- to calculate the pressure in the re‐
frigerant circuit and to actuate the control units downstream
(radiator fan control unit, engine control unit etc.) by way of the
data bus. These control units then activate e.g. the air condi‐
tioning system magnetic clutch - N25- , the radiator fans and
the motor accordingly ⇒ Vehicle diagnostic tester , “Self-di‐
agnosis” or “Guided Fault Finding” function and ⇒ Heating, air
Workshop Manual).

Senders for a connection without valve at refrigerant circuit
Note
♦ There are different versions of these senders with different

functions and designations. For example, the refrigerant pres‐
sure and temperature sender - G395- (as illustrated below) is
installed in the Audi Q7 e-tron ⇒ Heating, air conditioning;
Manual).
Possible designations for these senders

♦ Refrigerant pressure and temperature sender - G395- (e.g. on
the Audi Q7 e-tron)
♦ Refrigerant pressure and temperature sender 2 - G826- (e.g.
on the Audi Q7 e-tron)
♦ Refrigerant pressure and temperature sender 3 - G827- (e.g.
on the Audi Q7 e-tron)
There are different versions of these senders -A-; depending on
the version, they can currently only be distinguished by the part
number or by the printed designation -B- if the part number is the
same. Therefore pay attention to the correct assignment when
renewing the components; for part number and designation, refer
to ⇒ Electronic parts catalogue and ⇒ Heating, air conditioning;
ual).
When voltage is applied, these senders exchange information
with the corresponding control unit via the data bus (e.g. via the
“LIN bus”). The corresponding control unit uses this information
to calculate the pressure (and temperature) in the refrigerant cir‐
cuit; any faults detected are signalled to the control unit ⇒ Vehicle
diagnostic tester (“Guided Fault Finding”).
The corresponding control unit uses this information to calculate
the pressure in the refrigerant circuit and activates downstream
control units or components (control unit for radiator fan, pumps,
valves etc.) via the data bus according to requirements ⇒ Vehicle
diagnostic tester (“Guided Fault Finding”) and ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific Work‐
shop Manual).

3.6.8 Air conditioner compressor regulating

valve - N280-
The regulating valve is installed in the air conditioner compressor.
It is activated by the operating and display unit for front air con‐
ditioning system - E87- , the air conditioning system control unit -
J301- or the Climatronic control unit - J255- (possibly via the data
bus and an additional control unit, depending on the vehicle) ⇒
specific Workshop Manual). The regulating valve influences the
pressure on the low-pressure side and thus regulates the tem‐
perature in the evaporator.
Note
The air conditioner compressor regulating valve - N280- is part of

the air conditioner compressor and cannot be renewed separately
on all air conditioner compressors ⇒ Electronic parts catalogue
and
⇒ “9.1.8 Removing/installing and renewing air conditioner com‐
pressor regulating valve N280 ”, page 269 .
3.6.9 Air conditioner compressor speed send‐

er - G111-
Inductive sender
The sender pulses (4 per compressor revolution) and the engine
speed enable the operating and display unit for front air condi‐
tioning system - E87- or the Climatronic control unit - J255- to
calculate the belt slip.
If the belt slip exceeds a specified value, the air conditioner com‐
pressor is switched off by the control unit via the magnetic clutch.
Note
♦ This component is installed in Audi vehicles with compressor

drive via poly V-belt and Zexel compressor ⇒ Heating, air
Workshop Manual).
♦ The logo of the compressor manufacturer “Zexel” attached to
the air conditioner compressor was modified from “Zexel” to
“Valeo” from year of production 2006 onwards (change in
manufacturer's name).

3.6.10 Refrigerant temperature sender - G454-

The refrigerant temperature sender (with a temperature-sensitive
resistor) is installed, for example, in the high-pressure line near
the air conditioner compressor (only for certain vehicles manu‐
factured within a specific period, e.g. on Audi Q7 2007>).
In the refrigerant circuit, there is a direct relationship between
temperature and pressure. If there is insufficient refrigerant in the
circuit, the temperature in the refrigerant circuit during air condi‐
tioner operation will increase more sharply than envisaged for this
pressure.
Note
♦ Installed e.g. in Audi Q7 with certain engines ⇒ Heating, air

Workshop Manual) and ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations.
♦ The operating and display unit ( Climatronic control unit -
J255- ) evaluates the pressure and the temperature in the
refrigerant circuit and switches off the air conditioner com‐
pressor if the temperature increases above the value stored
for this pressure ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit (vehicle-specific Workshop Manual) and ⇒
Vehicle diagnostic tester (“Self-diagnosis” or “Guided Fault
Finding” function for air conditioner).
3.7 Electrical components not installed in

refrigerant circuit
⇒ “3.7.1 Radiator fan control unit J293 ”, page 55
3.7.1 Radiator fan control unit - J293-

This control unit switches the magnetic clutch and thus the air
conditioner compressor on and off. It switches the radiator fans
and calculates the pressure in the refrigerant circuit on vehicles
with a high-pressure sender - G65- . Refer to ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting locations and ⇒ Heating,
Workshop Manual).
3.8 Pressures and temperatures in refriger‐

ant circuit
Caution
♦ When working on the refrigerant circuit, observe generally

valid safety precautions and pressure vessel regulations.
The pressures and temperatures in the refrigerant circuit depend

on the instantaneous operating statuses (e.g. engine speed, ra‐
diator fan speed 1, 2, or 3, engine temperature, air conditioner
compressor on or off) as well as environmental influences (e.g.
ambient temperature, humidity, required cooling output).

On vehicles with air conditioner compressor regulating valve -

N280- the pressure on the low-pressure side is altered by actuat‐
ing -N280- .
On vehicles with an electrical air conditioner compressor - V470- ,
the pressure in the refrigerant circuit (high-pressure and low-
pressure sides) is regulated via the speed of the air conditioner
compressor.
On vehicles with an electrical air conditioner compressor - V470-
where the air conditioner is used not only to cool the passenger
compartment but also to cool high-voltage system components
and as a heat pump to heat the passenger compartment, different
conditions, pressures and temperatures apply in the refrigerant
circuit (e.g. on the Audi Q7 e-tron) ⇒ Vehicle diagnostic tester in
“Guided Fault Finding” mode and ⇒ Heating, air conditioning;
ual).
For this reason, the values given in the following table are for ref‐
erence only. They are attained at an engine speed of 1500 to 2000
rpm and an ambient temperature of 20 °C after about 20 minutes.
Refer to the vehicle-specific refrigerant circuit for the locations of
the pressure gauge connections ⇒ Heating, air conditioning; Rep.
At 20 °C with the engine not running, the pressure in the refrig‐
erant circuit is 4.7 bar ⇒ page 7 (vapour pressure table).
Note

⇒ “3.8.1 Refrigerant circuit with expansion valve”, page 56

⇒ “3.8.2 Refrigerant circuit with restrictor and reservoir”,
page 58
3.8.1 Refrigerant circuit with expansion valve
Note
Only applies with restrictions to vehicles with an electrical air con‐

ditioner compressor - V470- .
HP – High-pressure side of refrigerant circuit (HD in illustration)

LP – Low-pressure side of refrigerant circuit (ND in illustration)
Component State of refrigerant Pressure (bar) Temperature in degrees
centigrade
-1- Evaporator, from inlet Vapour approx. 1.2 bar1)1 approx. -7 °C 2)2
to outlet
-2- Expansion valve Liquid, expanded to va‐ approx. 14 bar approx. +55 °C (high-
pour pressure side), reduced
to -7 °C (low-pressure
side)
-3- High-pressure switch / Liquid approx. 14 bar approx. +55 °C
high-pressure sender


centigrade
-4- Service connection Liquid approx. 14 bar approx. +55 °C
(high-pressure side)
and
-5- Receiver
-6- Condenser From gas (at inlet) via va‐ approx. 14 bar From approx. +65 °C (at
pour to liquid (at outlet) inlet) to approx. +55 °C
(at outlet)
-7- High-pressure safety Gas approx. 14 bar approx. +65 °C
valve
and
-8- Air conditioner com‐
pressor (HP side)
-9- Air conditioner com‐ Gas approx. 1.2 bar1)1 approx. -1 °C 2)2
pressor (low-pressure
side)
-10- Damping chamber Gas approx. 1.2 bar1)1 approx. -1 °C 2)2
(not fitted on all vehicles)
and
-11- Service connection
(low-pressure side)
1) 1 - The pressure in a refrigerant circuit with a regulating air conditioner compressor is maintained at approx. 2 bar absolute (corresponding
to approx. 1 bar gauge) despite varying heat transfer and fluctuating engine speeds. This applies however only within the rated range of
the air conditioner compressor; if the rated range of the air conditioner compressor is exceeded, the pressure will increase
⇒ page 183 .
2) 2 - The temperature in a refrigerant circuit with a regulating air conditioner compressor is maintained within the regulating range of the
air conditioner compressor despite varying heat transfer and fluctuating engine speeds. This however only applies within the output range
of the air conditioner compressor. If the output limits of the air conditioner compressor are exceeded, the temperature will increase
⇒ page 183 .
Note
♦ Non self-regulating air conditioner compressors are switched

off by the relevant control unit via the air conditioner compres‐
sor regulating valve - N280- at evaporator temperatures below
0 °C.
♦ On vehicles with air conditioner compressor regulating valve -
N280- the pressure on the low pressure side is altered by
actuating the valve.
♦ On vehicles with two evaporators and two expansion valves,
the temperature and the pressure in the refrigerant circuit cor‐
respond to those on vehicles with only one evaporator and one
expansion valve (parallel connection).
♦ Depending on the version of the refrigerant circuit, a compo‐
nent with internal heat exchanger may be fitted (e.g. a refrig‐
erant line with internal heat exchanger is installed in the Audi
A4 2008 > and in the Audi A5 Coupé 2008 >). In the internal
heat exchanger, the hot refrigerant (liquid) flowing through the
high-pressure side gives off energy to the cold refrigerant
(gaseous or vaporous) flowing through the low-pressure side,
thus enhancing the efficiency of the air conditioner
⇒ page 35 .


1 - Evaporator
2 - Expansion valve
3 - High-pressure switch / high-
pressure sender
❑ Different versions de‐
pending on vehicle
4 - Service connection (high-
pressure side)
5 - Receiver
pending on vehicle
6 - Condenser
7 - High-pressure safety valve
8 - Air conditioner compressor
(low-pressure side)
10 - Damping chamber
❑ Not fitted on all vehicles
11 - Service connection (low-
pressure side)
3.8.2 Refrigerant circuit with restrictor and

reservoir
centigrade
-1- Air conditioner com‐ Gas Up to 20 bar Up to +70 °C
pressor (high-pressure
side)
-2- Condenser From gas to vapour to liq‐ Up to 20 bar Up to +70 °C
uid
-3- Restrictor From liquid to vapour HP side up to 20 bar, LP HP end up to +60 °C LP
side greater than 1.0 bar end warmer than -4 °C
-4- Evaporator From vapour to gas Greater than 1.0 bar Warmer than -4 °C
-5- Reservoir Gas
-6- Air conditioner com‐ Gas
pressor (low-pressure
side)
The pressures on the low-pressure side are maintained at approx.
2 bar absolute (corresponding to approx. 1 bar gauge) by the

“regulating” air conditioner compressor even at varying engine

speeds. This applies however only within the rated range of the
air conditioner compressor ; if the rated range of the air condi‐
tioner compressor is exceeded, the pressure will increase
⇒ page 183 .
Note
On vehicles with air conditioner compressor regulating valve -

N280- the pressure on the low pressure side is altered by actuat‐
ing the valve.


2 - Condenser
3 - Restrictor
4 - Evaporator
5 - Reservoir
(low-pressure side)

3.9 Tests and measurements performed

with pressure gauge
Pressure gauge scales
1- Temperature scale for refrigerant R134a CF3– CH2F or
CH2F– CF3
2- Pressure scale
Note

Pressure gauges may have one or more temperature scales in

addition to the pressure scale. The scale values for R134a are
assigned according to the vapour pressure table. As different re‐
frigerants develop different vapour pressures at the same tem‐
perature, there is a temperature scale for each refrigerant.
⇒ “3.9.1 Tests and measurements which can be performed using
pressure gauges”, page 60
3.9.1 Tests and measurements which can be

performed using pressure gauges
Refrigerant circuit pressure and temperature measurements
♦ The high-pressure gauge measures the pressure and tem‐
perature propagated evenly from the air conditioner compres‐
sor outlet via the condenser to the constriction (restrictor or
expansion valve) when the air conditioning system is switched
on.
♦ The low-pressure gauge measures the pressure and temper‐
ature propagated evenly from the constriction (restrictor or
expansion valve) via the evaporator to the inlet of the air con‐
ditioner compressor when the air conditioning system is
switched on.
Note
The relationship between pressure and temperature indicated on

the pressure gauges only applies in a refrigerant circuit containing
liquid or vapour, but not gas. In gaseous form, the temperature is
approx. 10 °C to 30 °C higher than the pressure gauge reading.
Detection of refrigerant in a closed vessel

In a closed vessel or in the refrigerant circuit, refrigerant R134a
is present if the temperature indicated on the pressure gauge
corresponds to the temperature of the refrigerant (standing liquid
assumes ambient temperature).
A closed vessel or a deactivated refrigerant circuit is empty if the
temperature indicated on the pressure gauge is below the tem‐
perature of the refrigerant.

Note
The relationship between pressure and temperature no longer

applies if no liquid is present and f the pressure is only built up by
gas.
3.10 Air conditioner service and recycling

units
Air conditioner service units for the extraction, cleaning and trans‐
fer of refrigerant for motor vehicle air conditioning systems are
currently available from various manufacturers.
Only certain air conditioner service stations (with appropriate ad‐
ditional equipment and various adapters if applicable) can be
used for cleaning the refrigerant circuit (flushing it with refrigerant
R134a) ⇒ page 88 .
⇒ “3.10.1 Classification of extraction systems”, page 61
⇒ “3.10.2 Charging systems that do not require a permit”,
page 62
3.10.1 Classification of extraction systems
WARNING
When working on the refrigerant circuit and handling refriger‐

ant, observe the generally valid safety precautions and pres‐
sure vessel regulations.
Note
♦ The air conditioner service and recycling units used in motor

vehicle workshops are extraction and charging systems that
do not require a permit (Group “3”) but which should only be
operated by qualified personnel. Instructions for the operation
and service of the devices may be found in the respective
manufacturer's documentation.
♦ Extraction and charging systems of groups “1” and “2” are not
used in motor vehicle workshops.
Group “3” extraction and charging systems:

Mobile extraction and charging systems for filling compressed-
gas vessels permanently connected to the system
The refrigerant or refrigerant/oil mixture is transferred to com‐
pressed-gas vessels which are permanently connected to the
mobile systems. In accordance with § 3 Para. 5 No. 3 of the Ger‐
man pressure vessel regulations (different regulations may apply
in other countries), compressed-gas vessels are classified as
pressure vessels in this case.
The charging systems:
– Do not require a permit.
– Do not require expert testing, as the gas is transferred to com‐
pressed-gas vessels which are classed as being pressure
vessels (On the other hand, a permit is required for the system
to fill a pressurised gas container for transfer to another party
from this pressurised container, and the permit requires an
examination.)

3.10.2 Charging systems that do not require a

permit
WARNING
When working on the refrigerant circuit and handling refriger‐

ant, observe the generally valid safety precautions and pres‐
sure vessel regulations.
Charging systems not requiring a permit are ones used for trans‐
ferring compressed gases to mobile compressed-gas vessels for
internal use only.
Note:
Some air conditioner service units are charging systems not re‐
quiring a permit. When working with such equipment, the refrig‐
erant is not transferred to mobile compressed-gas vessels, but
rather into a permanently installed charging cylinder with visible
level gauge and float switch.
Recommendation:
It is advisable to use a portable cylinder with visible level gauge
and high-pressure safety valve for surplus refrigerant for internal
use.
Various technical regulations (e.g. TRGS 400, TRGS 402, TRGS
407, TRGS 510, TRGS 725/TRBS 3145) must be noted when
filling compressed gases into other compressed-gas vessels.
3.11 Repair notes for refrigerant circuit
WARNING
♦ When working on the refrigerant circuit, observe generally

valid safety precautions and pressure vessel regulations.
Special tools and accessories:

The performance of proper workmanlike repairs on an air condi‐
tioning system
• Requires the use of special tools and materials as listed on
⇒ page 361 .
• Requires compliance with the basic instructions for use of leak
detectors ⇒ page 161 .
• Requires expert knowledge.
Note
Releasing refrigerant into the environment is prohibited

⇒ page 63 (laws and regulations).

4 Laws and regulations
Note
The laws and regulations listed below are applicable in Germany.

Different or additional laws and regulations may apply in other
countries.
⇒ “4.1 Laws and regulations”, page 63
4.1 Laws and regulations

By now the effects of climate change can be seen across the
globe. Climate protection is thus one of the most important prob‐
lems to be tackled. Solving this problem does however represent
an enormous challenge for everybody.
One aspect of the Kyoto protocol is the definition of the worldwide
climate protection targets. This protocol contains reduction tar‐
gets both for carbon dioxide and fluorinated greenhouse gases,
e.g. for refrigerant R134a, due to their high global warming po‐
tential.
A number of laws of relevance to the automotive industry have
been passed at European level, for example. In Germany for ex‐
ample, the climate protection regulation on chemicals additionally
came into force on 1st August 2008 to set down the European
legislation more precisely.
♦ Regulation (EC) no. 1005/2009
♦ Regulation (EC) no. 842/2006 (from 01.01.2015 onwards: reg‐
ulation (EU) no. 517/2014)
♦ Directive 2006/40/EC
♦ Climate protection regulation on chemicals, recycling and re‐
fuse law (for Germany).
Maintenance and repair work on air conditioner refrigerant circuits
Anyone performing maintenance and repair work on motor vehi‐
cle air conditioning systems must have received the relevant
instruction or attended a training course and be able to furnish
certification of the appropriate qualifications. Other or additional
regulations may apply in countries outside the European Com‐
munity.
However, the following is generally applicable:
Operation, maintenance, shut-down, take-back obligation
♦ With regard to the operation, repair and shut-down of products
containing refrigerants (which do not comply with the state of
the art), it is prohibited to allow the substances contained in
these to escape into the atmosphere.
♦ A record should be kept of the quantities used during operation
and for maintenance work ⇒ Audi-ServiceNet, HSO Environ‐
mental Protection to be able to submit certification of use to
the relevant authorities on request. According to a regulation
of the European parliament from 2005, it is no longer neces‐
sary to keep a record sheet in the EC. Other regulations may
apply in countries not belonging to the EC.
4. Laws and regulations 63

♦ Distributors of the substances and compounds specified in the

regulations listed above are obliged to take back such sub‐
stances and compounds after use or to ensure that these are
taken back by a third party specified by the distributor.
♦ The maintenance and shutdown of items containing refriger‐
ants listed in the regulations mentioned as well as acceptance
of return of the substances and preparations listed in these
regulations may only be undertaken by persons with the nec‐
essary expert knowledge and technical equipment.
Criminal offences and infringements of the law
♦ An infringement in terms of the regulations and laws men‐
tioned above is constituted by any wilful or negligent action
during the operation, maintenance or shutdown of items con‐
taining the refrigerants mentioned which allows substances
contained in these to escape into the atmosphere contrary to
the state of the art or by the wilful or negligent contravention
of the applicable regulations and laws mentioned above.
handling and filling compressed gases.
Note
Only excerpts from the TRGS are given in the following (sections
applicable to motor vehicle manufacturers and workshops).
♦ TRGS 400 (Risk assessment for activities involving hazardous

substances)
♦ TRGS 402 (Identification and assessment of the risks from
activities involving hazardous substances: inhalation expo‐
sure)
♦ TRGS 407 (Activities involving gases - risk assessment)
♦ TRGS 510 (Storage of hazardous substances in non-station‐
ary containers)
♦ TRBS 3145/TRGS 725 (Non-stationary compressed-gas ves‐
sels - filling, keeping, in-house transportation, emptying)
Note
♦ The technical regulations for compressed gases (TRG), haz‐

ardous substances (TRGS) and workplace safety (TRBS) re‐
flect the current state of the art in occupational safety and
hygiene as well as other ergonomic findings for the provision
and use of work equipment as well as for the operation of sys‐
tems requiring supervision and/or for activities involving haz‐
ardous substances.
♦ The specified technical regulations apply to Germany; in other
countries, rules and regulations differing from these may ap‐
ply.

handling and filling compressed gases.
♦ General provisions for charging systems
♦ Definition of terms and explanatory notes
♦ Constructing and operating charging systems
Charging systems

♦ Does not apply to vehicle manufacturers or workshops.

♦ Charging systems are systems for filling mobile compressed-
gas vessels. The charging system includes the premises and
facilities concerned.
♦ Charging systems requiring a permit are ones used to transfer
compressed gases to mobile compressed-gas vessels for
supplying to third parties.
♦ Charging systems not requiring a permit are ones used for
transferring compressed gases to mobile compressed-gas
vessels for internal use only.
Employees and employee instruction
– Employees are to be given instruction on the following topics
before beginning work and at regular, appropriate intervals,
however at least once a year:
• Hazards specifically associated with handling compressed
gases
• Safety regulations, particularly the applicable TRGS and
TRBS
• Procedures in the event of malfunction, damage and accidents
• The use of fire-extinguishing and protective equipment
• Operation and maintenance of the charging system on the ba‐
sis of the instructions for use
Charging systems may only be operated and maintained by per‐
sons:
♦ Aged 18 and above
♦ Possessing the necessary technical knowledge.
♦ Who can be relied upon to work diligently.
Note
Work under supervision may also be performed by persons who

fail to comply with the above-mentioned prerequisites.
Filling compressed-gas vessels (other technical regulations not

mentioned here may apply to vessels from other countries and
filling of these vessels).
♦ A compressed-gas vessel is only to be filled with the com‐
pressed gas declared on it and the quantity must comply with
the stipulated pressure, weight or volume data (refer to pres‐
sure vessel regulations).
♦ In the case of vessels approved for use with several types of
compressed gas, the compressed gas with which it is to be
filled and - if the compressed gas has a tc ≥ -10°C (tc = critical
temperature) - the maximum permissible charging weight in
line with TRGS must be marked on the vessel prior to con‐
nection for filling.
♦ Compressed-gas vessels marked with the maximum permis‐
sible charge pressure in bar at 15 °C must be filled manomet‐
rically. If, at the time of filling, the temperature is not 15 °C, the
pressure corresponding to the prevailing temperature must be
established; it must be ensured that the permissible charge
pressure at 15 °C is not exceeded in the compressed-gas
vessel. The charged vessels must be checked by way of ran‐
dom pressure measurements to determine possible overfill‐
ing.

♦ Compressed-gas vessels on which the maximum permissible

capacity is indicated by the net weight (filling weight, permis‐
sible weight of fill) in kilograms must be filled gravimetrically.
The vessels must be weighed during filling and subsequently
subjected to a weight check on special scales to detect pos‐
sible overfilling. Scales used for this purpose must be calibra‐
ted.
♦ Under certain conditions, gases with a tc greater than/equal to
+70°C may be transferred volumetrically from compressed-
gas vessels with a maximum volume of 150 l to compressed-
gas vessels with a volume of max. 1000 ccm. The stipulations
of the TRGS apply to filling workmen's cylinders with liquefied
gas.
♦ Different TRGS apply to vessels in vehicles:
– For gases with tc ≥ +70°C.
– For technical gas mixtures with tc ≥ +70°C.
– Liquefied extremely low-temperature compressed gases may
also be filled volumetrically (with the exception of vessels in
vehicles) if the charging system and/or the vessels is/are
equipped with devices for measuring or limiting the volume of
the charge and for measuring the temperature of the charge.
When filling volumetrically, it must be ensured that the per‐
missible charge weight indicated on the vessel is not excee‐
ded. To determine possible overfilling, the charged vessels
are to be checked gravimetrically on calibrated scales or volu‐
metrically, provided that the compressed gases are not highly
toxic. Volumetric checking requires the use of appropriate
equipment with completely separate charging and checking
devices.
♦ Charging and check measurements must be performed by
different people. Check measurements must be performed
immediately upon completion of the filling process.
♦ Overfilled vessels must be discharged immediately and safely
until the permissible filling quantity is reached. The com‐
pressed-gas fill must then be determined again.
♦ Certain parts of TRGS 407 do not apply or only apply to a
limited extent to vessels for liquefied, extremely low-tempera‐
ture compressed gases which are neither flammable nor toxic;
this does not affect the provisions of road traffic legislation.
♦ When filling compressed gas vessels with liquefied gases at
charging temperatures ≤ -20°C, the compressed gas vessel
(if the vessel material has not been tested for temperatures ≤
-20°C) is not to be released from the charging system for
transportation until the vessel wall temperature is ≤ +20°C.
Recycling and refuse law
♦ Regulations and rules for the handling and disposal of refrig‐
erants and refrigerant oils can be found in the climate protec‐
tion regulation on chemicals and in the recycling and refuse
law (applicable in Germany, different regulations and rules
may apply in other countries).
Disposal of refrigerant
Refrigerants intended for disposal must be transferred to marked
recycling cylinders, observing the permissible filling quantity. In
Germany, reference should be made for example to the climate
protection regulation on chemicals and the recycling and refuse
law (different regulations and rules may apply in other countries).
Disposal of refrigerant oil
Used refrigerant machine oils from systems with halogenated hy‐
drocarbons must be disposed of as waste requiring particular
care. They are not to be mixed with other oils or substances.

Proper storage and disposal must be ensured in line with local

regulations. In Germany, reference should be made for example
to the climate protection regulation on chemicals and the recycling
and refuse law (different regulations and rules may apply in other
countries) ⇒ Audi-ServiceNet, HSO Environmental Protection .
⇒ “4.1.1 Conversion of an R12 refrigerant circuit to an R134a re‐
frigerant circuit and servicing (retrofit)”, page 67
⇒ “4.1.2 Keeping refrigerant records”, page 67
4.1.1 Conversion of an R12 refrigerant circuit

to an R134a refrigerant circuit and serv‐
icing (retrofit)
Note
♦ For environmental reasons and on account of the correspond‐

ing legislation, refrigerant R12 can no longer be manufactured
or supplied. Refrigerant R134a has been developed as a re‐
placement for R12.
♦ However, air conditioning systems developed and designed
for refrigerant R12 cannot simply be charged with refrigerant
R134a. To ensure trouble-free operation of the air conditioning
system even after conversion, various components of the re‐
frigerant circuit must be renewed.
♦ A precise description of the conversion procedure and infor‐
mation on the servicing of converted refrigerant circuits can be
found in ⇒ Workshop Manual: Air conditioner with refrigerant
R12 Parts 2 and 3 (this Workshop Manual is only available in
hardcopy form).
4.1.2 Keeping refrigerant records

The environmental statistics law requires records to be kept on
the use of refrigerants exceeding a certain quantity per year.
Consequently, motor vehicle workshops may well have to provide
the relevant local authorities with information on their use of re‐
frigerant. It is therefore advisable to always keep a record sheet
⇒ Audi-ServiceNet, HSO Environmental Protection .
Note
♦ On the basis of a regulation of the European parliament from

2005, it is generally no longer necessary in the EC to keep a
record sheet for the quantity of refrigerant handled in motor
vehicle workshops. A record sheet is currently only necessary
as of an annual consumption of 50 kg or more (refer also to
directive (EC) No. 1005/2009 for example).
♦ As the relevant local authorities may demand information on
refrigerant consumption as of a certain quantity (currently as
of 20 kg per year), it is advisable to always keep an appropriate
record sheet.
♦ Other regulations may apply in countries not belonging to the
EC.

5 Refrigerant circuit
⇒ “5.1 Important repair notes for air conditioning systems”,
page 68
⇒ “5.2 Converting refrigerant circuits from refrigerant R12 to re‐
frigerant R134a ”, page 68
⇒ “5.3 Working with the air conditioner service station”,
page 69
⇒ “5.4 Blowing out refrigerant circuit with compressed air and ni‐
trogen ”, page 84
⇒ “5.5 Cleaning (flushing) refrigerant circuit with refrigerant
R134a”, page 88
⇒ “5.6 Tracing leaks in refrigerant circuit ”, page 161
5.1 Important repair notes for air condition‐

ing systems
• Air conditioners for refrigerant R12 may only be filled with re‐
frigerant R134a if certain prerequisites are satisfied
⇒ page 67 and ⇒ Workshop Manual: Air conditioner with re‐
frigerant R12 Part 2 and 3 . This Workshop Manual is only
available in hardcopy form.
• The refrigerant oils specifically developed for R134a and R12
refrigerant circuits are never to be mixed.
• Air conditioner service stations which come into contact with
the refrigerant should only be used for the intended refrigerant.
• The components of an R134a refrigerant circuit are accord‐
ingly labelled, marked with green stickers or designed (e.g. a
different thread) such that interchange with components for
refrigerant R12 is not possible.
• Within the engine compartment, on the bonnet catch striker
plate or in the plenum chamber there is an information plate
which states what refrigerant is used.
• Never mix different refrigerants.
Note
When working on the refrigerant circuit, please observe the in‐

formation given in the section “Basic rules for working on refrig‐
erant circuit”
⇒ “2.12 Basic rules for working on refrigerant circuit”, page 17 .
5.2 Converting refrigerant circuits from re‐

frigerant R12 to refrigerant R134a
CFC refrigerants are no longer used in the automotive industry.
For conversion of refrigerant circuits from R12 to R134a and
servicing converted circuits, refer to
⇒ Workshop Manual: Air conditioner with refrigerant R12 Parts 2
and 3 (this Workshop Manual is only available in printed form).

5.3 Working with the air conditioner service

station
Caution
♦ If there is a possibility that chemical substances (sealing

additives) for sealing leaks have been added to the refrig‐
erant circuit from which the refrigerant is to be extracted,
do not connect the air conditioner service station to this
refrigerant circuit and do not extract the refrigerant.
♦ Chemical substances (sealing additives) for sealing leaks
form deposits in the refrigerant circuit which will impair
operation of the air conditioning system and lead to failure
of the system (and of the air conditioner service station).
♦ Customers should be informed that the air conditioner in
their vehicle contains substances not approved by Audi
and that the system can therefore not be discharged and
serviced by your workshop.
5. Refrigerant circuit 69
Note
♦ Commercially available chemical substances (sealing addi‐

tives) for sealing refrigerant circuit leaks are not approved by
Audi AG. Damage to or malfunctioning of the air conditioner
or air conditioner service station cannot be precluded as no
tests have been performed to establish long-term action, ef‐
fectiveness and material compatibility.
♦ Commercially available sealing additives have different phys‐
ical and chemical properties. They may have a lasting detri‐
mental effect on operation of the air conditioner and air
conditioner service station or even be the cause of total failure.
♦ Audi objects to the use of chemical substances (sealing addi‐
tives) for sealing leaks in refrigerant circuits.
♦ Chemical substances (sealing additives) for sealing leaks in
the refrigerant circuit generally react with the ambient air or the
humidity contained in it. They cause malfunctioning of valves
and other components with which they come into contact on
account of deposits in the refrigerant circuit (and in the air
conditioner service station being used). These deposits can
no longer be completely removed from the components (not
even by cleaning/flushing with refrigerant R134a).
♦ Chemical substances (sealing additives) used to seal leaks in
refrigerant circuits usually cannot be detected from the out‐
side; mostly the stickers that are supposed to be attached to
identify these chemical substances are missing. Therefore, act
with caution when working on a vehicle whose past you are
not familiar with.
♦ On the accessories market, vessels with integrated filters are
available which are supposed to intercept these chemical sub‐
stances (additives used to seal leaks). As Audi are not aware
of the composition and thus the physical and chemical prop‐
erties of these substances, no information can be given here
as to the effectiveness and the separation rate of such filters.
♦ The sealant filter - VAS 6592- available as "Workshop equip‐
ment" provides a certain degree of protection for air condition‐
er service stations. This filter is incorporated between the air
conditioner service station and the service connection on the
low-pressure side of the vehicle refrigerant circuit (the air con‐
ditioner service station is not to be attached to the service
connection on the high-pressure side of the refrigerant circuit
for drainage, evacuation and measurement). The filter sepa‐
rates out certain substances added to the circuit to seal re‐
frigerant circuit leaks. It thus prevents the unimpeded and
unrestricted ingress of these substances into the air condi‐
tioner service station (together with the refrigerant and refrig‐
erant oil) where they would cause damage. Protection is
however only provided if the built-in filter is replaced at regular
intervals exactly as specified by the manufacturer in the ap‐
plicable instructions. As Audi do not approve the use of chem‐
ical substances (sealing additives) for sealing leaks in the
refrigerant circuit and the composition of such chemical sub‐
stances (sealing additives) marketed for example as so-called
“refrigerant circuit sealants” varies greatly, it is again not pos‐
sible to provide any information on the action and efficiency of
the sealant filter - VAS 6592- .
If air conditioner refrigerant circuit repair work has to be performed

on a vehicle on which chemical substances (sealing additives)
have been added to the refrigerant circuit to seal leaking compo‐
nents (or if you have good reason to believe that such substances
have been added), the customer (vehicle owner) must be notified
of the following:

♦ The air conditioner refrigerant cannot be extracted on account

of the substances added (sealing additives), as these could
damage the air conditioner service station. The refrigerant
must be extracted for example by a company authorised to
extract and then dispose of the contaminated refrigerant using
the appropriate equipment (e.g. a local refuse disposal com‐
pany specialising in the disposal of refrigerants).
♦ The air conditioning system can only be properly repaired by
renewing all the refrigerant circuit components which have
come into contact with the sealing additive. The sealing addi‐
tive may already have damaged certain refrigerant circuit com‐
ponents (e.g. the air conditioner compressor regulating valve
- N280- ) or lead to damage and subsequent failure shortly
after renewed start-up. Furthermore, sealing additive deposits
may subsequently come loose in the refrigerant circuit com‐
ponents and then cause the air conditioner to fail again (full
cleaning of these components with workshop equipment is
currently not possible).
Work on the air conditioner refrigerant circuit
⇒ “5.3.1 Important notes for working with the air conditioner serv‐
ice station”, page 71
⇒ “5.3.2 Connecting air conditioner service station for measuring
and testing”, page 72
⇒ “5.3.3 Discharging refrigerant circuit with air conditioner service
station”, page 73
⇒ “5.3.4 Evacuating refrigerant circuit with air conditioner service
station”, page 75
⇒ “5.3.5 Charging refrigerant circuit with air conditioner service
station”, page 80
⇒ “5.3.6 Starting up air conditioner after charging”, page 81
⇒ “5.3.7 Pouring refrigerant into reservoir (charging cylinder or
storage vessel) of air conditioner service station”, page 83
⇒ “5.3.8 Discharging air conditioner service station”, page 83
5.3.1 Important notes for working with the air

conditioner service station
Observe the following in order to operate the air conditioner serv‐
ice stations, currently available air conditioner service stations ⇒
Electronic parts catalogue (Tools; Workshop equipment/tools; Air
conditioning/heating):
– The fitted filter and dryer must be renewed by no later than
when the operational time specified in the related operating
instructions has been reached.
– If an air conditioner service station is also used to clean (flush)
the refrigerant circuit, the dryers and filters fitted must be re‐
newed more frequently ⇒ page 84 .
– Use only refrigerant oils which are also approved for the ve‐
hicle-specific refrigerant circuit (if applicable, add the refriger‐
ant oil directly to the refrigerant circuit). ⇒ Electronic parts
catalogue.
In cases of doubt about the composition of the refrigerant extrac‐
ted from the refrigerant circuit, this is not to be re-used even after
cleaning in the air conditioner service station.
– In such cases, discharge the air conditioner service station
⇒ page 178 , clean the system if necessary and renew the
filters, dryers and refrigerant oil.
– In Germany, for example, contaminated refrigerant can be re‐

turned to the refrigerant supplier in so-called recycling cylin‐
ders for treatment or environmentally friendly disposal (differ‐
ent or additional regulations may apply in individual countries).
Commercially available air conditioner service stations can be
classified in 2 groups:
♦ Air conditioner service stations which clean the refrigerant ex‐
tracted from a vehicle for re-use (so-called extraction and
recycling stations, for currently available air conditioner serv‐
ice stations) ⇒ Electronic parts catalogue (Tools; Workshop
equipment/tools; Air conditioning/heating).
♦ Air conditioner service stations which transfer extracted re‐
frigerant to recycling cylinders (for large-scale recycling);
these are referred to as extraction systems.
5.3.2 Connecting air conditioner service sta‐

tion for measuring and testing
• Work procedure may vary depending on the type of tools se‐
lected; therefore it is important to observe the tool-specific
operating instructions.
Note
The work procedure must always be performed as described in

the operating instructions of the air conditioner service station.
The filler hoses should be connected as follows to prevent air or

moisture from entering into the refrigerant circuit:
– On vehicles with high-voltage system, switch off (deactivate)
auxiliary air conditioner function ⇒ Owner's Manual and ⇒
Infotainment/MMI Operating Manual .
– Connect air conditioner service station to power supply.
– Unscrew sealing caps from service connections / connections
with valve ⇒ Heating, air conditioning; Rep. gr. 87 ; Refriger‐
ant circuit (vehicle-specific Workshop Manual).
– Evacuate filler hoses if necessary.
– Connect quick-release coupling to service connection of re‐
frigerant circuit.
WARNING
♦ Do not open the valves on the low or high-pressure end

with the engine running, as otherwise the air conditioner
compressor or the air conditioner service station could be
destroyed by a short circuit between the high and low-
pressure ends of the refrigerant circuit if the air condition‐
ing system is switched on.
– Only screw the handwheel into the quick-release coupling

adapter to the extent required to reliably open the valve in the
service connection (observe the pressure gauge; take care not
to open the valve too far).
– Start the engine and perform the intended tests and meas‐
urements.

– Compare the values determined to the specified measured

values ⇒ page 183 .
– Before detaching quick-release coupling, close it by screwing
out handwheel.
Vehicles with one service connection only:
Note
Screw valve adapters - V.A.G 1785/9- , -V.A.G 1785/10- or adapt‐

er set - V.A.G 1786- onto refrigerant circuit connections with valve
and bleed filler hoses while connecting to adapters (faintly audible
escape of refrigerant gas is permitted) ⇒ page 178 .
– The filler hose must be fitted with a valve opener for opening
valve in valve adapter.
On vehicles with high-voltage system and additional air condi‐
tioner functions (e.g. on the Audi Q7 e-tron):
Note
On vehicles with the “heat pump” and/or “high-voltage battery

cooling” function, high pressure is not available at the service
connection on the high-pressure side in all air conditioner oper‐
ating modes. On these vehicles, the pressure in the refrigerant
circuit on the high-pressure side can only be measured via the
pressure/temperature senders installed in the refrigerant circuit
(depending on the air conditioner operating mode) ⇒ Heating, air
Workshop Manual) and ⇒ Vehicle diagnostic tester (“Guided Fault
Finding”).
To check the various functions of these air conditioners:

– On the vehicle diagnostic tester, select the corresponding
function (“passenger compartment cooling”, “heat pump op‐
eration” or “high-voltage battery cooling”) and perform the
function according to requirements ⇒ Vehicle diagnostic tester
in “Guided Fault Finding” mode.
– On the vehicle diagnostic tester, select and read out the meas‐
urements from the various pressure/temperature senders in‐
stalled in the refrigerant circuit ⇒ Vehicle diagnostic tester in
5.3.3 Discharging refrigerant circuit with air

• Work procedure may vary depending on the type of tools se‐
lected; it is therefore important to observe the tool-specific
operating instructions.
• The refrigerant circuit must be discharged if you intend to re‐
move parts of the refrigerant circuit, if there is any doubt about
the quantity of refrigerant in the circuit or if safety precautions
require you to do so.
• All the necessary usage information for working with the re‐
frigerant air conditioner service station can be found in the air
conditioner service station operating instructions.
Discharging:

– Connect air conditioner service station to vehicle service con‐
nections according to operating instructions (refer to vehicle-
specific refrigerant circuit) and start up service station ⇒
Additionally on vehicles with electrically operated valves in the
refrigerant circuit which are not open when the system is de-ener‐
gised (e.g. on the Audi Q7 e-tron):
Note

tioner functions (“heat pump operation” or “high-voltage battery
cooling”), valves which are not open when the system is de-ener‐
gised may be fitted in the refrigerant circuit. These valves are
opened and closed e.g. via stepper motors and are not activated
after the ignition is switched off. However, for the refrigerant circuit
to be discharged fully, evacuated correctly and filled there must
be no separated areas; these valves must therefore be opened
before performing such work ⇒ Heating, air conditioning; Rep.
gr. 87 ; Refrigerant circuit (vehicle-specific Workshop Manual),
and ⇒ Vehicle diagnostic tester (“Guided Fault Finding”).
– Use the vehicle diagnostic tester to open the electrically acti‐

vated valves which are not open when the system is de-
energised ⇒ Vehicle diagnostic tester (“Guided Fault Find‐
ing”).
All vehicles:
– Drain the refrigerant circuit with the air conditioner service sta‐
tion in line with the corresponding operating instructions.
Caution
Risk of air conditioner compressor damage if the refrigerant

circuit is empty
Never start the engine when the refrigerant circuit is empty.
♦ Depending on the version of the air conditioner service
station, the pressure in the refrigerant circuit may be less
than 1 bar absolute following drainage.
♦ Depending on the version, the air conditioner compressor
may be damaged by running it when the pressure in the
refrigerant circuit is low.
♦ Never start the engine if the pressure in the refrigerant
circuit is below ambient pressure.
WARNING

discharged.

Note
♦ It is impossible to exclude the possibility that refrigerant oil may

be extracted from the refrigerant circuit along with the refrig‐
erant. To ensure air conditioner compressor lubrication, the
refrigerant oil in the circuit must be topped up with fresh oil
⇒ page 276 .
♦ On vehicles fitted with an air conditioner compressor without
magnetic clutch (with air conditioner compressor regulating
valve - N280- ), the engine should not be run for longer than
absolutely necessary with the refrigerant circuit empty; avoid
high engine speeds (with air conditioner compressor always
in operation).
♦ On vehicles with an air conditioner compressor without a mag‐
netic clutch, the engine should only be started following the
complete assembly of the refrigerant circuit (avoid high engine
speeds).
If the air conditioner compressor is switched on (or the refrig‐
erant circuit is discharged via the low-pressure side), the
pressure on the low-pressure side drops, the expansion valve
is opened and the refrigerant can flow to the low-pressure side.
♦ The quantity of refrigerant R134a extracted as displayed by
the air conditioner service station may differ from the amount
actually extracted depending on the version of the air condi‐
tioner service station, the mode in which the air conditioner
service station was last operated and the ambient temperature
etc. The quantity of refrigerant extracted as displayed by the
air conditioner service station is therefore only a guide to the
amount of refrigerant actually extracted from the refrigerant
circuit. Attention should also be paid to the operating instruc‐
tions and technical product description of the air conditioner
service station.
If, after drainage, work not requiring the air conditioner service
station is to be performed on the vehicle,
– disconnect the air conditioner service station from the refrig‐
erant circuit and switch it off.
If evacuating and re-charging refrigerant circuit after it is dis‐
charged, refer to ⇒ page 80 .
5.3.4 Evacuating refrigerant circuit with air

• The work procedure must always be performed as described
in the operating instructions of the air conditioner service sta‐
tion.
• Quantity of refrigerant oil in refrigerant circuit checked and if
necessary corrected ⇒ page 276 .
• Quantity of refrigerant in air conditioner service station
checked
The refrigerant circuit must be evacuated (emptied of air) before

it is charged with refrigerant. Moisture is also extracted from the
circuit.
Leaks can be detected on evacuating the refrigerant circuit.
Evacuating:
Caution
♦ Do not start the engine during the evacuating procedure

and while there is a vacuum in the refrigerant circuit.
♦ The air conditioner compressor may be damaged if the
engine is started whilst there is a vacuum in the refrigerant
circuit.
♦ Always charge the refrigerant circuit before starting the
engine.

– Connect filler hoses of air conditioner service station to vehicle
refrigerant circuit with quick-release coupling adapter (refer to
vehicle-specific refrigerant circuit) ⇒ Heating, air conditioning;
Manual).
– Screw in the handwheel of the quick-release coupling adapt‐
ers to the extent required to reliably open the valves of the
service connections (take care not to open the valve too far).
Note
If you intend to measured the pressure on only one side of the

refrigerant circuit after charging the system (on vehicles with a
service connection), use the valve adapter and filler hose with
valve opener ⇒ page 178 .


Note
♦ On vehicles with high-voltage system and additional air con‐

ditioner functions (“heat pump operation” or “high-voltage bat‐
tery cooling”), valves which are not open when the system is
de-energised may be fitted in the refrigerant circuit. These
valves are opened and closed e.g. via stepper motors and are
not activated after the ignition is switched off. However, for the
refrigerant circuit to be discharged fully, evacuated correctly
and filled there must be no separated areas; these valves must
therefore be opened before performing such work ⇒ Heating,
cific Workshop Manual), and ⇒ Vehicle diagnostic tester (“Gui‐
ded Fault Finding”).
♦ Non-return valves in the refrigerant circuit have a specific
holding pressure (approx. 0.1 bar or 100 mbar) in the forward
direction. All electrically activated valves must therefore be
open so that the refrigerant circuit can be evacuated fully (re‐
sidual pressure less than 5 mbar).

ing”).
All vehicles:
– Switch on air conditioner service station and evacuate the re‐
frigerant circuit for at least 30 minutes. In this process, the
pressure reading must be less than 10 mbar absolute (corre‐
sponding to a vacuum of 990 mbar).
Note
On the air conditioner service station V.A.G 1885 for currently

available air conditioner service stations ⇒ Electronic parts cata‐
logue (Tools; Workshop equipment/tools; Air conditioning/heat‐
ing), the two green LEDs light at this pressure, for example.
– Switch off air conditioner service station and allow to stand for
at least 1 hour.
• If the vacuum display (LED chain) does not change, the sys‐
tem is free of leaks and can be charged.
Note
♦ With V.A.G 1885 for example, for currently available air con‐
ditioner service stations ⇒ Electronic parts catalogue (Tools;
Workshop equipment/tools; Air conditioning/heating), a cur‐
rent vacuum display (LED) is only obtained after pressing the
Evacuation button again.
♦ If, with this air conditioner service station, the upper (green)
LEDs do not light immediately after switching on, either the
refrigerant circuit is leaking or there is still residual moisture/
refrigerant in the circuit.
Proceed as follows if the vacuum is not maintained or an ade‐

quate vacuum cannot be generated:
♦ The pressure in the refrigerant circuit only increases slowly
following evacuation, e.g. due to the evaporation of refrigerant
from the refrigerant oil.
– If it is not certain whether the refrigerant circuit is really leak-
proof, repeat evacuation and observe the vacuum display over
a lengthy period. Only charge circuit if vacuum is maintained.
– If it is certain that there are no leaks in the refrigerant circuit,
charging can be performed.
♦ In the event of a leak of such a magnitude that the ingress of
air on evacuation is already sufficient to prevent the air con‐
ditioner service station generating an adequate vacuum or the
vacuum gauge already indicates the ingress of air and the loss
of vacuum immediately after switching off the air conditioner
service station.
– Determine the leakage location in the refrigerant circuit as fol‐
lows:

Note
♦ A major leak can be determined for example by building up a

pressure of max. 15 bar in the refrigerant circuit with pure, dry
compressed air or with nitrogen ⇒ page 84 . If the leak is of
large enough, the location of the leak can be found due to the
noise of the gas escaping.
♦ Apply the compressed air or the nitrogen to the closed refrig‐
erant circuit by way of the service connection to which a quick-
release coupling adapter for service connections has been
attached.
♦ The quick-release coupling adapter for service connections
can be connected to the workshop compressed air system
using e.g. a modified filler hose -A- (e.g. with a 5/8"-18 UNF
thread, depending on thread on quick-release coupling adapt‐
er) and an appropriate adapter -B- ⇒ page 367 . To prevent
moisture, oil and dirt from the workshop compressed air sys‐
tem from entering the air conditioner refrigerant circuit, also
use a combination fine filter unit for the compressed air sys‐
tem, with an oil, dirt and water separator, as commonly used
for painting systems. Install this unit between the compressed
air system and the filler hose -A- ⇒ Electronic parts catalogue
(Tools; Workshop equipment/tools; Air conditioning/heating).
♦ Using a pressure gauge set with nitrogen pressure reducer
-1- (max. reducing pressure: 15 bar), a compressed-gas cyl‐
inder -3- filled with nitrogen can be connected to the service
connection (quick-release coupling adapter for service con‐
nections attached) at the closed refrigerant circuit
⇒ page 366 with a filler hose -2- (e.g. with a 5/8"-18 UNF
thread).
– Slowly increase the pressure in the refrigerant circuit to max.

15 bar.
WARNING
♦ There may be an uncontrolled flow of nitrogen out of the

cylinder.
♦ Only use pressure reducer for nitrogen cylinders (max.
working pressure 15 bar).
♦ For leak detection with nitrogen (max. permissible oper‐
ating pressure 15 bar) always work with pressure reducers
for nitrogen cylinders.
♦ Use appropriate extraction units to draw off the gas mix‐
ture escaping from the components.
– Determine the leakage location by way of the noise caused by

the escaping gas at this point.
– Eliminate the leakage.
– Evacuate and again observe the vacuum display over a period
of hours. Only charge circuit if vacuum is maintained.
♦ In the event of a leakage of a magnitude permitting the ingress
of no or very little air and the air conditioner service station can
generate an adequate vacuum. The vacuum display does not
increase or only increases very slowly after switching off the
air conditioner service station, indicating that air is only in‐
gressing and vacuum is being lost through a minor leak.
– Pour 100 g of refrigerant into the circuit and use an electronic

leak detector to locate and eliminate any leaks ⇒ page 163 or
pour in refrigerant with UV contrast medium and use the leak
detection system VAS 6201 to search for and eliminate the
leak in the refrigerant circuit ⇒ page 165 .
– If necessary, discharge refrigerant circuit ⇒ page 73 .
– Evacuate refrigerant circuit and observe vacuum display again
over a period of hours. Only charge circuit if vacuum is main‐
tained.
5.3.5 Charging refrigerant circuit with air con‐

ditioner service station
Note
The entire refrigerant charge can be added to either the high or

low-pressure side ⇒ page 276 .

tion.
• Before pouring in refrigerant, correct the quantity of refrigerant
oil ⇒ page 276 .
• When charging the refrigerant circuit, the air conditioner serv‐
ice station must be on the same level as the vehicle in which
the refrigerant circuit is to be charged (maximum difference 50
cm). Depending on the design of the air conditioner service
station , an excessive difference in height could lead to differ‐
ences between the quantity of refrigerant displayed and that
actually poured in. The charging accuracy of the air condition‐
er service station may change.
– Evacuate refrigerant circuit with air conditioner service station
⇒ page 75 .
Note

before performing such work ⇒ Heating, air conditioning; Rep.
gr. 87 ; Refrigerant circuit (vehicle-specific Workshop Manual),
and ⇒ Vehicle diagnostic tester (“Guided Fault Finding”).

ing”).

All vehicles:
– Unscrew the handwheel at the quick-release coupling adapter
(to close it).
– Allow refrigerant to flow into filler hose.
– Take the charging cylinder reading.
– Screw in the handwheel at the quick-release coupling adapter
(to open it) and charge with the specified quantity of refriger‐
ant.
– Switch off air conditioner service station.
On vehicles for which the Service Schedule specifies that the re‐
frigerant circuit must be drained/filled after a specific mileage:
– After performing the work, enter “air conditioner refilled” in the
appropriate field in the Service Schedule ⇒ Maintenance ta‐
bles and/or “Maintenance” manual.
Note
Draining and filling the refrigerant circuit is only specified as main‐

tenance work in the Service Schedule for certain vehicles (cur‐
rently e.g. for the Audi Q7 e-tron and Audi A6 e-tron).
5.3.6 Starting up air conditioner after charging
Note
♦ If it has been removed, give the mechanically driven air con‐

ditioner compressor approx. 10 turns by hand prior to initial
start-up (on or after installation, e.g. before fitting the belt) to
prevent damage caused by fluid lock when first switched on
(any oil in the air conditioner compressor cylinder is forced out
by the cranking action).
♦ If it has been removed, the electrically driven air conditioner
compressor is to be started up, prior to initial commissioning
of the air conditioner and following charging, by way of the
“Basic setting, compressor run-in” function of the Guided Fault
Finding routine ⇒ Vehicle diagnostic tester, “Guided Fault
This guards the air conditioner compressor against damage
caused for example by fluid lock when first switched on (any
oil in the combustion chamber of the air conditioner compres‐
sor is forced out).
♦ The mechanically driven air conditioner compressor is driven
via a belt or shaft by the engine. The electrically driven air
conditioner compressor is driven via an electric motor attach‐
ed directly to the air conditioner compressor (e.g. on vehicles
with hybrid drive).
Starting up air conditioner with mechanically driven air conditioner

compressor
– Start the engine with the air conditioner compressor switched
off (version with magnetic clutch).
– Set the air conditioner compressor to minimum output, i.e.
"Econ" or A/C off mode (version with no magnetic clutch with
regulating valve).
– Wait for idling speed to stabilise.
– Switch on air conditioner compressor and operate system for
at least two minutes at idling speed.
– If necessary, check pressures in refrigerant circuit with air
conditioner service station.
– Switch off engine.
– Screw out handwheel on quick-release coupling adapter.
– Detach filler hoses from refrigerant circuit.
– Screw the sealing caps back on.
Starting up air conditioner with electrically driven air conditioner
compressor
– Start up air conditioner compressor via “Basic setting, com‐
pressor run-in” function of Guided Fault Finding ⇒ Vehicle
diagnostic tester in “Guided Fault Finding” mode for air con‐
ditioner and battery regulation .
– Via respective control unit, enable activation of electrically op‐
erated valves (for opening or closing) which are not open
without current for air conditioner operation ⇒ Vehicle diag‐
nostic tester (“Guided Fault Finding”).
Note

before performing such work. After completing work on the re‐
frigerant circuit, the valves which are activated e.g. via stepper
motors must be re-activated via the corresponding control unit ⇒
All vehicles:
– If necessary, check the pressures in the refrigerant circuit with
the air conditioner service station on completion of basic set‐
ting ⇒ page 72 .
– Screw out handwheel on quick-release coupling adapter.
– Detach filler hoses from refrigerant circuit.
– Screw the sealing caps back on.

5.3.7 Pouring refrigerant into reservoir (charg‐

ing cylinder or storage vessel) of air con‐
tion.
• A certain quantity of refrigerant is specified as charge for each
air conditioning system. To ensure that neither too much nor
too little refrigerant is added (either would reduce the cooling
output), the charging cylinder has a scale indicating the weight
for example.
• The volume of a refrigerant changes as a function of pressure.
The scale must therefore be set according to the pressure in
the charging cylinder.
Note
Do not completely empty the charging cylinder or storage vessel,

as the liquid column boundary layer cannot be traced in the indi‐
cator tube during filling (outside visible range).
WARNING
Do not overfill. A completely filled charging cylinder or storage

vessel will explode when the temperature rises.
5.3.8 Discharging air conditioner service sta‐

tion
Note
♦ If it is necessary to discharge the air conditioner service station

(e.g. due to extraction of contaminated refrigerant), always re‐
new all filters and dryers (do not remove filter and dryer from
the air-tight packaging until immediately before installation to
minimise absorption of moisture).
♦ Refrigerant cylinders filled with contaminated or used refrig‐
erant are termed “recycling cylinders ”.
♦ Always evacuate recycling cylinders before initial filling with
refrigerant (if there is air in a refrigerant vessel it must not be
filled with refrigerant).
♦ Do not mix various types of refrigerant (refrigerant mixtures
cannot be recycled and must be disposed of). If there is any
doubt about the composition of the contents of the container,
the refrigerant recycling company must be informed.
Caution
♦ Observe the applicable regulations, technical rules and

laws when charging recycling cylinders (compressed gas
cylinders).
♦ Recycling cylinders must never be overfilled. If recycling
cylinders are overfilled, the gas cushion is too small to
withstand the expansion of liquid caused by exposure to
heat. There is a risk of bursting.
♦ For your own safety, only use recycling cylinders with a
built-in safety valve.
♦ Recycling cylinders must be weighed on calibrated scales
during the filling process. The maximum permissible ca‐
pacity is 75% (filling factor 0.75) of the filling weight indi‐
cated on the recycling cylinder (the possibility of refriger‐
ant oil entering the recycling cylinder along with the
refrigerant cannot be ruled out).
5.4 Blowing out refrigerant circuit with com‐

pressed air and nitrogen
The best way of removing moisture, impurities and old refrigerant
oil from the refrigerant circuit without any unnecessary loss of re‐
frigerant and without extensive assembly work, whilst at the same
time ensuring environmental compatibility, is to clean (flush) the
refrigerant circuit with refrigerant R134a or to blow it out with
compressed air and nitrogen.
Note
♦ Blowing out the refrigerant circuit with compressed air and ni‐
trogen usually involves far more work than cleaning (flushing)
with refrigerant R134a. Cleaning (flushing) with refrigerant
R134a also provides far better cleaning of the components.
Flushing should therefore always be employed in the event of
complaints (blowing out should only be applied when dealing
with certain problems and for particular components).
♦ Under certain conditions it may, for example, be sufficient to
blow out specific components (e.g. individual refrigerant pipes
or refrigerant hoses) with compressed air and nitrogen (for in‐
stance to force old refrigerant oil out of individual components
following removal).
♦ Certain impurities are impossible or difficult to remove properly
from the refrigerant circuit using compressed air. Such impur‐
ities can be removed for example by cleaning (flushing) with
refrigerant R134a ⇒ page 88 .
♦ A maximum working pressure of 15 bar is not to be exceeded
when blowing out (corresponds to the pressure prevailing in a
charged refrigerant circuit at an ambient temperature of ap‐
prox. 60 °C; use pressure reducer for compressed air as well
if applicable).

WARNING
♦ There may be an uncontrolled flow of nitrogen out of the

cylinder.
♦ Only use pressure reducer for nitrogen cylinders (max.
working pressure 15 bar).
♦ Use appropriate extraction units to draw off the gas mix‐
ture escaping from the components.
– Always flush or blow out components in direction opposite to

refrigerant flow.
Note
The restrictor, expansion valve, air conditioner compressor, re‐

ceiver and reservoir cannot be flushed with compressed air and
nitrogen.
– In the case of condensers fitted with a desiccant cartridge in

the integrated receiver, this cartridge is to be removed.
Note
♦ On vehicles with condensers with an integrated receiver/des‐

iccant cartridge which cannot be renewed separately, the
condenser must be renewed after it has been cleaned (flush‐
ed).
♦ Depending on the version, receivers on which the desiccant
cartridge can be renewed separately may be provided with an
additional filter element which may have to be renewed to‐
gether with the desiccant cartridge.
– First flush out the old refrigerant oil and dirt with compressed
air and then use nitrogen to remove the moisture from the
components.
– For adapter for connecting pressure hose to refrigerant circuit,
refer to ⇒ page 178 .
Observe the following to prevent oil and moisture from the com‐
pressed-air system from entering the refrigerant circuit.
– The compressed air must be passed through a compressed-
air purifier to clean and dry it. Use is therefore to be made of
filter and dryer for compressed air (included in scope of deliv‐
ery as tool for painting work).
– For refrigerant lines with thread or union nut at connection, use
adapters from adapter set - V.A.G 1785- ( adapter - V.A.G
1785/1- to adapter - V.A.G 1785/8- ) for connecting 5/8" -18
UNF filler hoses (some of these adapters are also contained
in the adapter set for refrigerant circuits - VAS 6338/1- ).
– For refrigerant lines with no thread or union nut at connection
(for connecting adapters), use adapters from adapter set for
refrigerant circuits - VAS 6338/1- or commercially available
blow-out gun with rubber mouthpiece.
Note
♦ The refrigerant circuit is only to be blown out with compressed

air and then nitrogen if no means of cleaning (flushing) the
refrigerant circuit with refrigerant R134a are available or if
flushing of individual components would involve too much
work (blowing minor impurities and small quantities of mois‐
ture out of refrigerant pipes for example is not particularly time-
consuming).
♦ Compressed air/nitrogen emerging from components must be
drawn off using an appropriate system (e.g. workshop extrac‐
tor).
The refrigerant circuit (or individual components) is/are to be

blown out if no means of cleaning (flushing with refrigerant
R134a) are available or if cleaning (flushing with refrigerant
R134a) seems inappropriate
– In the event of dirt or other impurities in individual circuit com‐
ponents
– If vacuum reading is not maintained on evacuating a leak-free
refrigerant circuit (pressure build-up due to moisture in refrig‐
erant circuit)
– If the refrigerant circuit has been left open for longer than the
normal assembly time (e.g. following an accident).
– If pressure and temperature measurements in the refrigerant
circuit indicate that there is moisture in the circuit.
– If it is uncertain how much refrigerant oil is in the refrigerant
circuit.
– If the air conditioner compressor has to be renewed on ac‐
count of internal damage (e.g. noise or no output).
Note
For vehicles with an electrically driven air conditioner compressor,

see the notes on renewing the electrical air conditioner compres‐
sor - V470- (damage to the air conditioner compressor electronics
does not always mean that the refrigerant circuit has to be
cleaned) ⇒ page 262
– If stipulated by the vehicle-specific Workshop Manual after re‐

newing certain components
Note
Certain impurities and old refrigerant oil are impossible or difficult

to remove properly from the refrigerant circuit using compressed
air. Such impurities can be removed for example by cleaning
(flushing) with refrigerant R134a ⇒ page 88 .

⇒ “5.4.1 Blowing out refrigerant circuit”, page 87
5.4.1 Blowing out refrigerant circuit
Note
♦ In the case of vehicles on which the refrigerant lines have no

threads for connection of adapters V.A.G - 1785- , use is to be
made, for example, for blowing out the individual components
of a blow-out gun with rubber mouthpiece or an adapter from
the VW/Audi passenger vehicle adapter set - VAS 6338/1- .
Take special care not to damage the connections by crushing
or scratching them when using an air pistol with a rubber end
piece.
♦ The evaporator must be blown out via the connection for the
low-pressure line (large diameter) after removing the expan‐
sion valve or restrictor.
♦ Always clean (flush or blow out) components in the opposite
direction to the refrigerant flow.
♦ Check expansion valve and renew if dirty or corroded.
♦ If dark, sticky deposits cannot be removed with compressed
air, clean (flush) the components concerned with refrigerant
R134a or renew.
♦ Thin, light grey deposits on the insides of pipes do not impair
the function of the components.
♦ After flushing, always renew receiver or reservoir and restric‐
tor. In the case of condensers fitted with a desiccant cartridge
in the integrated receiver, this cartridge must be renewed.
♦ On vehicles with condensers with an integrated receiver/des‐
iccant cartridge which cannot be renewed separately or which
are not available as a replacement part, the condenser must
be renewed after cleaning (flushing) ⇒ Electronic parts cata‐
logue and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refriger‐
ant circuit (vehicle-specific Workshop Manual).
After blowing out refrigerant circuit:

– Renew the following components (vehicle-specific): restrictor
and reservoir, expansion valve and receiver / desiccant car‐
tridge ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
parts catalogue .
– Depending on the problem, renew air conditioner compressor
pressor (vehicle-specific Workshop Manual) and ⇒ Electronic
parts catalogue , or drain off remaining refrigerant oil from air
conditioner compressor (removed earlier) ⇒ page 258 (re‐
newing components of refrigerant circuit) and add specified
quantity of new refrigerant oil again ⇒ page 317 (approved
refrigerant oils and refrigerant oil capacities).
Note
♦ Replacement compressors contain a certain specified quantity

of refrigerant oil. For vehicles with two evaporators, it may be
necessary to additionally add a certain quantity of refrigerant
oil to the circuit ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐
frigerant circuit (vehicle-specific Workshop Manual) and
⇒ page 317 (approved refrigerant oils and refrigerant oil ca‐
pacities).
♦ If the air conditioner compressor is not supposed to be re‐
newed, the refrigerant oil quantity in the air conditioner com‐
pressor must be topped up in line with the specified capacity
(pour out refrigerant oil and add the specified quantity to the
air conditioner compressor or the refrigerant circuit again)
⇒ page 258 (Renewing refrigerant circuit components) and
⇒ page 317 (Approved refrigerant oils and refrigerant oil ca‐
pacities).
– Completely re-assemble the refrigerant circuit ⇒ Heating, air

Workshop Manual).
– Evacuate and charge the refrigerant circuit as specified
⇒ page 75 and ⇒ page 80 .
– Start up air conditioner as specified ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Refrigerant circuit; Starting up air conditioner
after charging refrigerant circuit (vehicle-specific Workshop
Manual) and ⇒ page 81 .
5.5 Cleaning (flushing) refrigerant circuit

with refrigerant R134a
Caution
♦ If there is a possibility that chemical substances (sealing

additives) for sealing leaks have been added to the refrig‐
erant circuit to be flushed, do not connect the air condi‐
tioner service station to this refrigerant circuit and do not
clean (flush) this refrigerant circuit.
♦ Chemical substances (sealing additives) for sealing leaks
form deposits in the refrigerant circuit which will impair
operation of the air conditioning system and lead to failure
of the system (and of the air conditioner service station).
♦ Customers should be informed that the air conditioner in
their vehicle contains substances not approved by Audi
and that the system can therefore not be cleaned (flushed)
and serviced by your workshop.

Note
♦ Audi objects to the use of chemical substances (sealing addi‐

tives) for sealing leaks in refrigerant circuits.
♦ Chemical substances (sealing additives) for sealing leaks in
the refrigerant circuit generally react with the ambient air or the
humidity contained in it. They cause malfunctioning of valves
and other components with which they come into contact on
account of deposits in the refrigerant circuit (and in the air
conditioner service station being used). These deposits can‐
not be completely removed from the components affected
(even by cleaning/flushing). Therefore the refrigerant circuit
can only be serviced by renewing all components that have
come into contact with the chemical substances.
♦ Chemical substances (sealing additives) used to seal leaks in
refrigerant circuits usually cannot be detected from the out‐
side; mostly the stickers that are supposed to be attached to
identify these chemical substances are missing. Therefore, act
with caution when working on a vehicle whose past you are
not familiar with.
• The best way of removing moisture, impurities (e.g. abrasion

from a defective air conditioner compressor) and old refriger‐
ant oil without any unnecessary loss of refrigerant and without
extensive assembly work, whilst at the same time ensuring
environmental compatibility, is to clean (flush) the refrigerant
circuit with refrigerant R134a.
The refrigerant circuit is to be flushed:
– If there is any dirt or similar in the circuit.
– If vacuum reading is not maintained on evacuating a leak-free
refrigerant circuit (pressure build-up due to moisture in refrig‐
erant circuit)
– If the refrigerant circuit has been left open for longer than the
normal assembly time (e.g. following an accident).
– If pressure and temperature measurements in the refrigerant
circuit indicate that there is moisture in the circuit.
– If it is uncertain how much refrigerant oil is in the refrigerant
circuit.
– If the air conditioner compressor has to be renewed on ac‐
count of internal damage (e.g. noise or no output).
Note
♦ For vehicles with an electrically driven air conditioner com‐

pressor, see the notes on renewing the electrical air condi‐
tioner compressor - V470- (damage to the air conditioner
compressor electronics does not always mean that the refrig‐
erant circuit has to be cleaned) ⇒ page 262
♦ If a defective air conditioner compressor is replaced by a com‐
pressor from a different manufacturer, it is important to check
whether the refrigerant oil already in the refrigerant circuit
(from the removed compressor) is also approved for the new
compressor. If a different refrigerant oil is approved for the new
air conditioner compressor than for the removed compressor,
the refrigerant circuit must be flushed ⇒ page 319 .
– If stipulated by the vehicle-specific Workshop Manual after re‐

newing certain components
Tools required
♦ Air conditioner service station with flushing kit (these air con‐
ditioner service stations feature the additional function “Flush‐
ing refrigerant circuit” and the necessary flushing kit for
refrigerant circuits) ⇒ Electronic parts catalogue (Tools; Work‐
shop equipment/tools; Air conditioning/heating).
♦ VW/Audi passenger vehicle adapter set - VAS 6338/1-
⇒ page 111 and ⇒ Electronic parts catalogue (Tools; Work‐
Note
♦ If no air conditioner service station with flushing kit is available

⇒ Electronic parts catalogue (Tools; Workshop equipment/
tools; Air conditioning/heating) and depending on the version
of the air conditioner service station being used, the refrigerant
circuit can also be cleaned (flushed with refrigerant R134a)
using the refrigerant circuit flushing kit ⇒ Electronic parts
catalogue , (Tools; Workshop equipment/tools; Air condition‐
ing/heating) however this must then be performed manually.
⇒ page 96
♦ Use can be made for vehicles with screw connections at the
refrigerant circuit of the adapter - V.A.G 1785/7- and adapter
- V.A.G 1785/8- from the VW/Audi passenger vehicle adapter
set - VAS 6338/1- . Two adapters - V.A.G 1785/8- are required
for a vehicle with screw connections at the air conditioner
compressor and reservoir.
♦ The adapter set for refrigerant circuits - VAS 6338/1- also con‐
tains a short filler hose - VAS 6338/31- with 5/8 -18 UNF
connections and a large inside diameter (commercially avail‐
able).
Preparations
– Discharge the refrigerant circuit ⇒ page 73 .
– Remove air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Air conditioner compressor (vehicle-specific
Workshop Manual).
Vehicle with restrictor and reservoir
– Remove restrictor (vehicle-specific) and re-connect pipes ⇒
– Remove reservoir (vehicle-specific) and re-connect pipes (for
this purpose, use adapter and filler hose - VAS 6338/31- from
adapter set for refrigerant circuits - VAS 6338/1- )
⇒ page 111 and ⇒ Heating, air conditioning; Rep. gr. 87 ;

Note
♦ Although it may be possible to flush the reservoir (depending

on version), its large internal volume means that it holds too
much liquid refrigerant. When this refrigerant is extracted the
reservoir ices up severely, the refrigerant only evaporates very
slowly and the extraction process takes too long.
♦ Although it may be possible to flush the receiver (depending
on version; refer to the description for the specific vehicle), its
large internal volume means that it may hold too much liquid
refrigerant. When this refrigerant is extracted the reservoir ices
up severely, the refrigerant only evaporates very slowly and
the extraction process takes too long.
Vehicle with expansion valve and receiver

– Remove receiver (vehicle-specific; not necessary on all vehi‐
cles) and re-connect pipes (for this purpose, use adapter and
filler hose - VAS 6338/31- from adapter set for refrigerant cir‐
cuits - VAS 6338/1- ) ⇒ page 111 and ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific
Workshop Manual).
Note
♦ Depending on the design, the receiver can be flushed (if nec‐

essary, remove desiccant cartridge installed in receiver)
♦ If the receiver is attached to the condenser (e.g. on the Audi
A3 from model year 2004 onwards), it must not be removed
for flushing (its design makes it suitable for flushing, and it is
only renewed after flushing) ⇒ page 111 and ⇒ Heating, air
Workshop Manual).
♦ In the case of condensers with an integrated receiver / desic‐
cant cartridge which cannot be renewed separately or which
are not available separately, the condenser is to be renewed
after flushing. On these vehicles, renew the condenser to‐
gether with the receiver ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit (vehicle-specific Workshop Manual)
– On vehicles with a desiccant cartridge in the receiver at the

condenser (vehicle-specific), remove the desiccant cartridge
and re-seal the opening at the receiver ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific Work‐
shop Manual).
– Remove the expansion valve (vehicle-specific) and replace it
with an adapter from the adapter set for refrigerant circuits -
VAS 6338/1- ⇒ page 111 and ⇒ Heating, air conditioning;
Manual).
– On vehicles with one or more shut-off valves/non-return
valves, remove the valves and replace with suitable adapters
(or hand shut-off valves) from the VW/Audi passenger vehicle
adapter set - VAS 6338/1- ⇒ page 111 , ⇒ Heating, air con‐

Workshop Manual).
Note
If there is no suitable adapter for the expansion valve in the VW/

Audi passenger vehicle adapter set - VAS 6338/1- , the removed
expansion valve can also be drilled open (the old expansion valve
generally has to be renewed and is therefore no longer needed).
Note
♦ Item -3- can be disregarded.

♦ When drilling open the expansion valve, make sure that the
openings -2- and -4- in the valve -1- are offset.
♦ If you do not do so, the sealing surface on the expansion valve
-1- could be damaged when drilling open the valve; the ex‐
pansion valve can then no longer be used for setting up the
flushing circuit.
Drill open expansion valve.

Note
♦ Before drilling open, remove the control element and then drill
open the expansion valve using a suitable drill bit for example
(bit diameter e.g. 6.0 mm).
♦ Certain components have to be removed from the expansion
valve before drilling it open.
♦ There are different expansion valve versions with different de‐
signs. With version -A-, the parts -B-, -C- and -D- have to be
removed for example. Then separate part -E- (control ele‐
ment) from part -D-. After doing so, use a suitable bit to drill
open the expansion valve in area -F-.
♦ With version -G-, the parts -H-, -I- and -K- must be removed
for example and the area -L- then drilled open using a suitable
bit.
– Remove swarf remnants from the expansion valve after drilling

open.
– Re-install the parts -B-, -C- and -D- with version -A- or part
-H- with version -G-.
Note
On vehicles with two evaporators, the circuit to the second evap‐

orator must be separated from the circuit of the first evaporator
and flushed in a separate operation ⇒ page 111 and ⇒ Heating,
Workshop Manual).
Flushing
– Check that the air conditioner service station contains at least
6 kg of refrigerant R134a.
Note
If applicable, switch on the heater attached to the air conditioner

service station for the refrigerant cylinder installed in the air con‐
ditioner service station prior to the first flushing operation (to
increase the pressure in the refrigerant cylinder) and switch it off
again before the first extraction operation during the flushing cy‐
cle.
– Discharge the used oil container of the air conditioner service

station.
– Connect the supply hose (high-pressure end) of the air con‐
ditioner service station with an adapter to the low-pressure
pipe to the air conditioner compressor (pipe with larger diam‐
eter) ⇒ page 111 .
– Connect the return hose (low-pressure or suction end) of the
air conditioner service station to the outlet of the refrigerant
circuit flushing kit.
– Connect the inlet of the refrigerant circuit flushing kit with an
adapter to the high-pressure pipe to the air conditioner com‐
pressor (pipe with smaller diameter) ⇒ page 111 .
Note
♦ The components are always (with the exception of the electric

air conditioner compressor) flushed in the opposite direction
to the refrigerant flow during air conditioner operation
⇒ page 98 .
♦ When flushing, impurities from the refrigerant circuit ingress
into the refrigerant circuit flushing kit and the air conditioner
service station, where they are retained in the built-in filters
and dryer. Depending on the nature of the impurities, these
components should be renewed more frequently in accord‐
ance with the operating instructions for the air conditioner
service station or the refrigerant circuit flushing kit.
♦ Depending on the nature and severity of the contamination of
the flushed refrigerant circuits, the filter in the refrigerant circuit
flushing kit should be renewed at the latest after 5 to 10 flush‐
ing cycles (flushed vehicles). After flushing a severely conta‐
minated refrigerant circuit (the refrigerant oil from the refriger‐
ant circuit is black and viscous or there is a lot of swarf in the
refrigerant circuit), renew the filter. In the case of such severely
contaminated refrigerant circuits it is also appropriate to flush
the circuit again after renewing the filter.
♦ Depending on the nature of the impurities, dirt (used refriger‐
ant oil and abrasion from air conditioner compressor) accu‐
mulates at the sight glass of the refrigerant circuit flushing kit.
If applicable, clean this sight glass after flushing and flush the
refrigerant circuit again in one operation as a check (one op‐
eration is then sufficient).
♦ Liquid refrigerant cannot be routed through the expansion
valve, restrictor and desiccant bag of certain receivers at the
necessary rate. Therefore remove these components and re‐
place them with adapters if applicable ⇒ Heating, air condi‐
Workshop Manual).
♦ Adapters for connection of air conditioner service station and
for bridging certain refrigerant circuit components
⇒ page 111 .
– Connect flushing circuit in vehicle (depending on refrigerant

circuit) ⇒ page 111 .
Vehicles with 2 evaporators in refrigerant circuit:
Note
♦ The refrigerant circuit is cleaned in 2 flushing cycles (first the

section with the evaporator in the front heater and air condi‐
tioning unit and then the section with the evaporator in the rear
heater and air conditioning unit) ⇒ page 111 .
♦ On vehicles with two evaporators, the circuit to the second
evaporator must be separated from the circuit of the first evap‐
orator and flushed in a separate operation ⇒ page 111 and ⇒

Vehicles with high-voltage system (without additional air condi‐

tioner functions, e.g. Audi A3 e-tron, Audi Q5 hybrid)
Note
♦ The refrigerant circuit is cleaned in 2 flushing cycles (first the

section with the evaporator in the front heater and air condi‐
tioning unit and then the section with the heat exchanger for
high-voltage battery / evaporator in the battery cooling mod‐
ule) ⇒ page 111 .
♦ On vehicles with two evaporators or with an evaporator and a
heat exchanger, the circuit to the second evaporator or to the
heat exchanger must be separated from the circuit of the first
evaporator using hand shut-off valves and flushed in a sepa‐
rate operation ⇒ page 111 and ⇒ Heating, air conditioning;
Manual).
♦ A flushing cycle currently comprises three consecutive flush‐
ing operations (depending on the program in the air condition‐
er service station) ⇒ page 96 .
– Close or open the appropriate hand shut-off valves installed,

depending on which section of the refrigerant circuit you wish
to flush in this flushing cycle.
– Close or open the installed electrically operated valves via the
routine stored in the vehicle's corresponding control unit, de‐
pending on which section of the refrigerant circuit you wish to
flush in this flushing cycle.
Vehicles with high-voltage system (with additional air conditioner
functions such as heat pump operation, e.g. Audi Q7 e-tron)
Note
♦ The refrigerant circuit is cleaned in multiple flushing cycles

Refrigerant circuit; Cleaning air conditioner refrigerant circuit .
♦ To perform the flushing procedure, the circuit is separated into
multiple sections, which are then flushed in one flushing cycle
each. The circuit is separated by activation of the installed
electrically activated valves and via the installed manual shut-
off valves (must be activated manually) ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrigerant circuit; Cleaning air
conditioner refrigerant circuit .
♦ A flushing cycle currently comprises three consecutive flush‐
ing operations (depending on the program in the air condition‐
er service station) ⇒ page 96 .
♦ The layout of the different flushing circuits for these vehicles
is described in the corresponding vehicle-specific Workshop
Manual ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit; Cleaning air conditioner refrigerant circuit .
– Close or open the hand shut-off valves installed, depending

on which section of the refrigerant circuit you wish to flush in
this flushing cycle ⇒ Heating, air conditioning; Rep. gr. 87 ;
– Close or open any installed electrically operated valves via the

routine stored in the vehicle's corresponding control unit, de‐
pending on which section of the refrigerant circuit you wish to
flush in this flushing cycle ⇒ Vehicle diagnostic tester in “Gui‐
ded Fault Finding” mode and ⇒ Heating, air conditioning; Rep.
gr. 87 ; Refrigerant circuit; Cleaning air conditioner refrigerant
circuit .
All vehicles
– Switch on the air conditioner service station and flush the re‐
frigerant circuit (duration approx. 1 to 1.5 hours for one flushing
cycle with three flushing operations).
Note
♦ The flushing operation is to be performed in line with the op‐

erating instructions for the air conditioner service station ⇒
Operating instructions for air conditioner service station .
♦ Depending on the version of the air conditioner service station,
the used oil container may only hold approx. 125 cm 3 of re‐
frigerant oil. If a system with a larger refrigerant oil quantity is
to be flushed, it may be necessary to empty the used oil con‐
tainer after the first flushing operation in a flushing cycle.
♦ Observe the refrigerant flowing back out of the refrigerant cir‐
cuit into the air conditioner service station. Refrigerant circuit
cleaning has not been completed until the refrigerant flowing
through the inspection port of the refrigerant circuit flushing kit
into the air conditioner service station is clear and completely
colourless.
♦ During flushing, the entire refrigerant oil is rinsed out of the
refrigerant circuit (with the exception of slight residue in the
evaporator, for example; this can however be ignored).
♦ In the case of extremely severe contamination, it may be nec‐
essary to perform flushing twice (two flushing cycles with three
flushing operations each).
Sequence of flushing operation (sequence takes place automat‐

ically in line with air conditioner service station program)
♦ After switch-on, the flushing circuit (refrigerant circuit with con‐
necting hoses and refrigerant circuit flushing kit) is initially
evacuated and the refrigerant circuit checked for leaks De‐
pending on the version of the air conditioner service station,
manual switching to next step may be necessary ⇒ Operating
instructions for air conditioner service station .
♦ A specified quantity of refrigerant (e.g. 5 kg) is added to the
evacuated refrigerant circuit via the high-pressure end of the
air conditioner service station (in the direction opposite to the
normal flow direction during air conditioner operation and thus
on the low-pressure end of the vehicle refrigerant circuit) or
refrigerant is added until the refrigerant circuit and the inspec‐
tion ports of the refrigerant circuit flushing kit have been com‐
pletely filled with liquid refrigerant (depending on the version
of the air conditioner service station, the system detects that
there has been no further inflow of refrigerant over a certain
period for example).
♦ Once the specified quantity of refrigerant has been added, the
heater of the refrigerant circuit flushing kit may be switched on
for example depending on the version of the air conditioner
service station and the refrigerant circuit flushing kit (only if the
refrigerant is extracted in gaseous form from the refrigerant
circuit flushing kit).

♦ After the refrigerant has been extracted, the heater of the re‐
frigerant circuit flushing kit is switched off (if fitted). Depending
on the version, the refrigerant circuit may be briefly evacuated
again and, following evacuation, the refrigerant oil extracted
from the refrigerant circuit is separated by the air conditioner
service station.
♦ The refrigerant charging, extraction (and evacuation) process
is repeated twice (in other words it is implemented a total of
three times) ⇒ Operating instructions for air conditioner serv‐
ice station .
♦ Following extraction for the third time, the flushing circuit is
evacuated depending on the version of the air conditioner
service station.
– After flushing is completed, check the sight glass(es) of the
refrigerant circuit flushing kit. If these are contaminated, clean
as necessary according to the operating instructions for the
refrigerant circuit flushing kit or air conditioner service station.
Perform flushing again as a check (duration of approx. 30 min.
is sufficient) ⇒ Operating instructions for air conditioner serv‐
ice station .
– Check the pressure in the refrigerant circuit. There must not
be any positive pressure in the refrigerant circuit (evacuate
briefly again if necessary).
– Detach the connections to the air conditioner service station
from the vehicle refrigerant circuit (there must not be any pos‐
itive pressure in the refrigerant circuit).
– Renew the following components (vehicle-specific): restrictor
and reservoir, expansion valve and receiver / desiccant car‐
tridge in receiver ⇒ Heating, air conditioning; Rep. gr. 87 ;
– Depending on the problem, renew air conditioner compressor
parts catalogue , or drain off remaining refrigerant oil from air
conditioner compressor (removed earlier) ⇒ page 258 (re‐
newing components of refrigerant circuit) and add specified
quantity of new refrigerant oil again ⇒ page 317 (approved
refrigerant oils and refrigerant oil capacities).
Note
♦ Replacement compressors contain a certain specified quantity

of refrigerant oil. For vehicles with two evaporators, it may be
necessary to additionally add a certain quantity of refrigerant
oil to the circuit ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐
frigerant circuit (vehicle-specific Workshop Manual) and
⇒ page 317 (approved refrigerant oils and refrigerant oil ca‐
pacities).
♦ If the air conditioner compressor is not supposed to be re‐
newed, the refrigerant oil quantity in the air conditioner com‐
pressor must be topped up in line with the specified capacity
(pour out refrigerant oil and add the specified quantity to the
air conditioner compressor or the refrigerant circuit again)
⇒ page 258 (Renewing refrigerant circuit components) and
⇒ page 317 (Approved refrigerant oils and refrigerant oil ca‐
pacities).
– Completely re-assemble the refrigerant circuit ⇒ Heating, air

Workshop Manual).

– Start up air conditioner as specified ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Refrigerant circuit; Starting up air conditioner
after charging refrigerant circuit (vehicle-specific Workshop
Manual) and ⇒ page 81 .
⇒ “5.5.1 Block diagrams for various flushing circuits”, page 98
⇒ “5.5.3 Adapters for connecting flushing circuits”, page 111
⇒ “5.5.2 Flushing electrically driven air conditioner compressor
(removing refrigerant oil)”, page 106
5.5.1 Block diagrams for various flushing cir‐

cuits
Note
♦ The arrows in the following illustrations indicate the direction

of refrigerant flow on flushing (during flushing, the refrigerant
flows in the direction opposite to that in air conditioner opera‐
tion; the high-pressure end of the air conditioner service sta‐
tion is thus connected to the low-pressure connection of the
refrigerant circuit to the air conditioner compressor).
♦ The block diagrams illustrate a refrigerant circuit with restrictor
and reservoir and a refrigerant circuit with expansion valve,
receiver and a second evaporator (optional extra for certain
vehicles).
♦ Depending on the design of the air conditioner service station,
non-return valves may be fitted between the refrigerant circuit
and the air conditioner service station (to guarantee the correct
direction of refrigerant flow on flushing).
Flushing circuit on vehicles with high-voltage system

Refrigerant circuit with restrictor and reservoir ⇒ page 98
Refrigerant circuit with expansion valve, receiver and second
evaporator ⇒ page 102
⇒ page 105
⇒ page 106
Refrigerant circuit with restrictor and reservoir
Note
On vehicles with a restrictor and reservoir, the restrictor and res‐

ervoir are removed, and the lines unfastened to remove the
restrictor are assembled again. The pipe connections to the res‐
ervoir removed are connected together with two adapters and the
filler hose - VAS 6338/31- (from the adapter set for refrigerant
circuits - VAS 6338/1- ).

1 - Air conditioner service sta‐

tion
❑ With electronics and a
flushing program, e.g.
Air conditioner service
station with flushing kit
⇒ Electronic parts cata‐
logue (Tools; Workshop
equipment/tools; Air
conditioning/heating).
❑ If use is made of an air
conditioner service sta‐
tion with no flushing pro‐
gram, the process is to
be implemented man‐
ually (evacuation, 3x
flushing with at least 4
kg of refrigerant each
time, extraction of refrig‐
erant again, evacua‐
tion).
2 - Refrigerant hose of air con‐
❑ From the high-pressure
side of the air condition‐
er service station (gen‐
erally red coloured) to
the connection for the
low-pressure side of the
sor at the refrigerant cir‐
cuit (larger diameter)
3 - Adapter for connection
(low-pressure side) at refriger‐
ant circuit
pending on vehicle
⇒ page 111
❑ From adapter set for refrigerant circuits - VAS 6338/1-
4 - Connection (low-pressure side) at refrigerant circuit
❑ Different versions depending on vehicle ⇒ page 111
❑ At refrigerant line from air conditioner compressor to reservoir
5 - Connection to reservoir
❑ At refrigerant line from air conditioner compressor to reservoir
6 - Adapter for bridging reservoir after removal
7 - Filler hose for refrigerant ⇒ page 111
❑ For example filler hose - VAS 6338/31- (from adapter set for refrigerant circuits - VAS 6338/1- )
8 - Adapter for bridging reservoir after removal
9 - Connection to reservoir
10 - Evaporator
11 - Fitting location for restrictor
❑ Restrictor removed.
❑ Removing restrictor ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific Work‐
shop Manual)
12 - Bolt connection in refrigerant line
❑ Screw back together after removing restrictor ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit
13 - Condenser
14 - Connection (high-pressure side) at refrigerant circuit
15 - Adapter for connection (high-pressure side) at refrigerant circuit
16 - Filler hose to refrigerant circuit flushing kit
❑ From connection (high-pressure side) of air conditioner compressor at refrigerant circuit (smaller diam‐
eter) to inlet of flushing kit for refrigerant circuits
17 - Refrigerant circuit flushing kit
❑ Different versions and different designs of the refrigerant circuit flushing kit ⇒ Electronic parts catalogue
❑ With filter, sight glass, safety valve, heater, refrigerant vessel etc. (depending on version)
❑ Depending on the design of the air conditioner service station and the refrigerant circuit flushing kit, a
non-return valve may be fitted at the outlet of the refrigerant circuit flushing kit (to guarantee the correct
direction of refrigerant flow when flushing).
❑ Depending on the design of the refrigerant circuit flushing kit, a connection for a service coupling for
refrigerant circuits may be fitted at the inlet (and possibly also at the outlet) of the flushing kit (instead of
a 5/8-18 UNF external thread). If a service connection with valve is fitted at the outlet of the flushing kit,
this valve must be fully open when the service connection is connected (if the valve is not fully open this
creates a constriction). If there is a connection for a service coupling at the inlet of the flushing device,
modify the inlet so that the refrigerant hose that comes from the vehicle can be directly connected (a
service coupling and a valve in the inlet of the flushing device creates a constriction, which hinders the
flow of refrigerant out of the vehicle into the flushing device and therefore hampers the flushing process).

Caution
Danger of flushing kit
outlet icing up if a valve
is fitted but not fully open.
If♦a valve is fitted in the
connection but not fully
open, this creates a con‐
striction which obstructs
the flow of refrigerant in
the flushing process and
which may ice up due to
excessive cooling.
If♦there is a service con‐
nection with valve at the
outlet of the flushing kit,
this valve must be fully
open during the flushing
process.
If♦excessive cooling
(icing-up) occurs at the
outlet of the flushing kit
during the flushing proc‐
ess, abort the flushing
process and extract the
refrigerant from the flush‐
ing kit and from the vehi‐
cle via the high-pressure
and low-pressure sides.
Then check the valve in
the outlet of the flushing
kit and repair it if neces‐
sary.
Danger of flushing kit in‐
let icing up in the event of
a constriction caused by
a service coupling and a
valve fitted in the service
connection.
Remove
♦ the service con‐
nection fitted to this con‐
nection and connect the
service hose from the ve‐
hicle directly (without
constriction) to the flush‐
ing kit, using an adapter if
necessary (this depends
on the thread at the flush‐
ing kit inlet).
18 - Refrigerant hose of air conditioner service station

❑ From low-pressure side of air conditioner service station (usually blue) to outlet of flushing kit for refrig‐
erant circuits

Refrigerant circuit with expansion valve, receiver and second

evaporator
Note
♦ This block diagram shows a refrigerant circuit with expansion

valve, receiver and a second evaporator (optional extra for
certain vehicles).
♦ On vehicles with expansion valve and receiver, the expansion
valve is removed and replaced with an adapter. Depending on
the vehicle, the receiver is also removed and the pipe con‐
nections to the receiver are connected using two adapters and
a filler hose.
♦ On vehicles with only one evaporator, the components from
item “16” onwards are not fitted / are not required.

tion
flushing program, Air
tion with flushing kit ⇒
Electronic parts cata‐
flushing with at least 4
kg of refrigerant each
tion).
(low-pressure side) at refriger‐
ant circuit
pending on vehicle
⇒ page 111
4 - Connection (low-pressure side) at refrigerant circuit
5 - Adapter for removed expansion valve


6 - Evaporator
7 - Connection to receiver
❑ Not fitted on vehicles with a desiccant cartridge in the receiver at the condenser or with a receiver installed
in the condenser ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific Workshop
Manual).
8 - Adapter for bridging removed receiver
❑ Not necessary on all vehicles
9 - Filler hose for refrigerant ⇒ page 111
❑ For example filler hose - VAS 6338/31- (from adapter set for refrigerant circuits - VAS 6338/1- )
10 - Condenser
❑ If a receiver with desiccant cartridge is fitted at the condenser, the desiccant cartridge must be removed
(seal receiver at or in condenser again following removal) ⇒ Heating, air conditioning; Rep. gr. 87 ;
❑ If the receiver is attached directly to the condenser, flush the system before removing and renewing the
receiver ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific Workshop Manual).
Note
On certain vehicles, the receiver is

integrated into the condenser, and
the desiccant cartridge cannot be
renewed separately or is not availa‐
ble separately. On these vehicles,
renew the condenser together with
the receiver / desiccant cartridge af‐
ter flushing ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrigerant
circuit (vehicle-specific Workshop
Manual) and ⇒ Electronic parts
catalogue .
11 - Connection (high-pressure side) at refrigerant circuit

12 - Adapter for connection (high-pressure side) at refrigerant circuit

Caution
excessive cooling.
process.
sary.
connection.
Remove
ing kit inlet).

erant circuits
16 - Adapter for sealing outlet to second evaporator
❑ Only required for certain vehicles with “second evaporator” as optional extra
17 - Adapter for sealing outlet to second evaporator

18 - Connection (low-pressure side) at refrigerant circuit to second evaporator

❑ Only fitted on certain vehicles with “second evaporator” as optional extra
19 - Connection (high-pressure side) at refrigerant circuit to second evaporator
20 - Adapter for expansion valve (removed) at second evaporator
21 - Second evaporator

Note
♦ The refrigerant circuit is flushed in one or two flushing cycles,

depending on the circuit’s set-up.
♦ On vehicles without a heat exchanger for the high-voltage bat‐
tery (⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit; System overview - refrigerant circuit ), the refrigerant
circuit is flushed in one flushing cycle ⇒ page 102 .
♦ On vehicles with a heat exchanger for the high-voltage bat‐
tery / evaporator in the battery cooling module (⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - refrigerant circuit ), the refrigerant circuit is flushed in
two flushing cycles (first the section with the evaporator in the
heater and air conditioning unit, front, and subsequently the
section with the heat exchanger for the high-voltage battery/
evaporator in the battery cooling module)
⇒ “5.5.3 Adapters for connecting flushing circuits”,
page 111 .
♦ On vehicles with two evaporators or with an evaporator and a
heat exchanger, the circuit to the second evaporator or to the
heat exchanger must be separated from the circuit of the first
evaporator using hand shut-off valves and flushed in a sepa‐
rate operation
⇒ “5.5.3 Adapters for connecting flushing circuits”, page 111
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant cir‐
cuit (vehicle-specific Workshop Manual).
is similar to the layout on a vehicle with 2 evaporators
⇒ page 102 .


Note
♦ The refrigerant circuit is cleaned in multiple flushing cycles

♦ To perform the flushing procedure, the circuit is separated into
multiple sections, which are then flushed in one flushing cycle
each. The circuit is separated by activation of the installed
electrically activated valves and via the installed manual shut-
off valves (must be activated manually) ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrigerant circuit; Cleaning air
conditioner refrigerant circuit .
is described in the corresponding vehicle-specific Workshop
Manual ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit; Cleaning air conditioner refrigerant circuit .
5.5.2 Flushing electrically driven air condition‐

er compressor (removing refrigerant oil)
Notes on removing refrigerant oil from the electrically driven air
conditioner compressor (by flushing)
Note
♦ With the electrically driven air conditioner compressor, the re‐

frigerant oil cannot be poured out in the same way and to the
same extent as with the mechanically driven air conditioner
compressor. There is no oil drain plug and the internal struc‐
ture means that, depending on the version, it may only be
possible to pour out a small amount of refrigerant oil (or even
none at all). Depending on the version of the air conditioner
compressor and how it is stored, approx. 30 to 80 cm 3 of re‐
frigerant oil may remain in the air conditioner compressor after
the pouring operation (the electric air conditioner compressor
cannot be turned). Depending on the problem, the air condi‐
tioner compressor must therefore be flushed in order to re‐
move the refrigerant oil and determine the quantity of
refrigerant oil in the air conditioner compressor
⇒ “9.1.3 Renewing air conditioner compressor without having
to clean refrigerant circuit”, page 262 .
♦ On the electrically driven air conditioner compressor, the re‐
frigerant oil can be removed by flushing in the flow direction
(flushing in the opposite direction is not possible on account
of the built-in valves).
♦ For the flushing procedure, position the air conditioner com‐
pressor so that t.he connection for the refrigerant line on the
high-pressure side is as low down as possible.
♦ The electrically driven air conditioner compressor must be

flushed if there is a possibility that there is too much refrigerant
oil in the refrigerant circuit or in order to remove contaminated
(moisture-laden) refrigerant oil from the air conditioner com‐
pressor. In these cases, the refrigerant circuit must also be
flushed to clean it and allow the correct quantity of refrigerant
oil for the refrigerant circuit to be set once again
⇒ “10.2.2 Refrigerant oil capacities”, page 321 .
♦ If an electrically driven air conditioner compressor is renewed,
it is not always necessary to flush the refrigerant circuit. The

quantity of refrigerant oil in the removed air conditioner com‐

pressor can be determined by flushing the removed air con‐
ditioner compressor. The quantity of refrigerant oil in the new
air conditioner compressor must then be matched to the quan‐
tity flushed out of the old air conditioner compressor (plus 10
cm 3) by pouring out the excess
♦ To determine the quantity of refrigerant oil in the removed air
conditioner compressor, the refrigerant oil must be flushed out
of the air conditioner compressor to be removed and the flush‐
ed quantity measured (empty the vessels for old oil provided
at the air conditioner service station before flushing the air
conditioner compressor). Refrigerant oil must then be poured
out of the new air conditioner compressor until the quantity
remaining in the new air conditioner compressor corresponds
to the quantity of refrigerant oil flushed out from the old air
conditioner compressor (plus 10 cm 3). Dispose of refrigerant
oil flushed out of the defective air conditioner compressor and
poured out of the new air conditioner compressor ⇒ Audi
ServiceNet, HSO Environmental Protection (observe local
regulations).
♦ The air conditioner compressor to be newly installed must be
flushed if the quantity of refrigerant oil that can be poured out
of it is insufficient. After flushing, the air conditioner compres‐
sor to be installed must be filled up with the same quantity of
new refrigerant oil as was flushed out of the old air conditioner.
Example: If 120 cm3 of refrigerant oil was flushed out of the
removed air conditioner compressor, and the new compressor
contains 200 cm3 (see type plate and
⇒ “10.2.2 Refrigerant oil capacities”, page 321 ), 110 cm3 (120
cm3 minus 10 cm3) must be poured out of the new compressor
so that the refrigerant circuit contains the correct quantity of
refrigerant oil after the new compressor is installed. If the re‐
quired quantity of refrigerant oil cannot be poured out, then the
air conditioner compressor to be newly installed must also be
flushed. The new air conditioner compressor must then be fil‐
led up with the same quantity of refrigerant oil as was previ‐
ously flushed out of the old air conditioner compressor.
Flushing the electrically driven air conditioner compressor
Note
Depending on the air conditioner compressor, a new compressor

can be filled with a larger quantity of refrigerant oil (e.g. 290
cm3 on the Audi Q7 e-tron); refer to the manufacturer's label on
the air conditioner compressor and
⇒ “10.2.2 Refrigerant oil capacities”, page 321 ). Before flushing
new air conditioner compressors filled with more than 100 cm3,
pour out as much refrigerant oil as possible. Reason: Depending
on the version of the air conditioner service station, the quantity
of oil which can be separated in one operation may be limited (e.g.
150 cm3). Further notes ⇒ Item 5 (page 108)


tion
flushing program, Air
tion with flushing kit ⇒
Electronic parts cata‐
flushing with at least
2 kg of refrigerant each
tion).
(low-pressure side) to air con‐
ditioner compressor
pending on vehicle
⇒ page 111
❑ Use the adapter from the VW/Audi passenger vehicle adapter set - VAS 6338/1- (here adapter - VAS
6338/41- ).
4 - Refrigerant line
❑ For connecting air conditioner compressor to adapter ⇒ Item 3 (page 108)
Note
♦ A refrigerant line must only be

used if an adapter - VAS
6338/41- is not available.
♦ If an adapter - VAS 6338/41- for
setting up the flushing circuit is
not available, remove e.g. the re‐
frigerant line to the condenser
from the vehicle (or use a refrig‐
erant line with part number 7L6
820 744 AD) ⇒ Electronic parts
catalogue .
5 - Electrically driven air conditioner compressor

❑ The air conditioner compressor is flushed in flow direction (from the low-pressure end inlet to the high-
pressure end outlet)
❑ To flush as much refrigerant oil as possible out of the air conditioner compressor, the compressor should
be positioned with the high-pressure end outlet as low down as possible when flushing

Caution
Danger of impairing op‐
eration of the air condi‐
tioner service station
(depending on version
and quantity of refriger‐
ant oil in the air condi‐
tioner compressor).
Depending
♦ on the ver‐
sion of the air conditioner
service station, the quan‐
tity of oil which can be
separated in one opera‐
tion may be limited (e.g.
100 cm3). Observe the
operating instructions
and technical product de‐
scription for the air condi‐
tioner service station.
Depending
♦ on the air
conditioner compressor,
a new compressor can
be filled with a larger
quantity of refrigerant oil
(e.g. 290 cm3 on the Audi
Q7 e-tron)
⇒ “10.2.2 Refrigerant oil
capacities”, page 321
and
⇒ “9.1.3 Renewing air
conditioner compressor
without having to clean
refrigerant circuit”,
page 262 .
Before
♦ flushing new air
conditioner compressors
filled with more than 150
cm3, pour out as much
refrigerant oil as possible
(into a clean container,
via the high-pressure and
low-pressure connec‐
tion). This prevents the
oil separator of your air
tion from being overfilled
ess.
Then
♦ flush any remaining
refrigerant oil out of the
sor.
Note
If you pour the clean refrigerant oil

out of a new air conditioner com‐
pressor into a clean container and
then seal the container so that it is
air-tight, you can re-use this oil to
adjust the quantity of refrigerant oil
in the refrigerant circuit.

6 - Refrigerant line
❑ For connecting air conditioner compressor to adapter ⇒ Item 7 (page 110)
Note
♦ A refrigerant line must only be

used if an adapter - VAS
6338/40- is not available.
♦ If an adapter - VAS 6338/40- for
setting up the flushing circuit is
not available, use e.g. a refriger‐
ant line with part number
7L6 820 721 BF or
4G0 260 701 AB ⇒ Electronic
parts catalogue .
7 - Adapter for connecting (high-pressure side) to air conditioner compressor

❑ Use the adapter from the VW/Audi passenger vehicle adapter set - VAS 6338/1- (here adapter - VAS
6338/40- ).

Caution
excessive cooling.
process.
sary.
connection.
Remove
ing kit inlet).

erant circuits
5.5.3 Adapters for connecting flushing circuits

♦ The following table lists the various adapters required for con‐
necting the air conditioner service station to the refrigerant
circuit for flushing and for bridging the removed receiver or
reservoir and expansion valve (vehicle-specific).
♦ Use a filler hose with 5/8 -18 UNF connections (short version
e.g. filler hose - VAS 6338/31- ) to connect the two adapters

fitted instead of the reservoir or receiver removed earlier (con‐

tained in adapter set for refrigerant circuits - VAS 6338/1- ).
♦ If a flushed refrigerant circuit is not supposed to be re-assem‐
bled immediately after flushing, leave the adapters in place at
the connections and seal the connections at the adapters with
the caps - VAS 6338/30- (from the adapter set for refrigerant
circuits - VAS 6338/1- ).
♦ Depending on the version of the air conditioner compressor
and the production period, different connection and sealing
methods may have been used for the refrigerant circuit ⇒
Block or screw connections
– Screw connection -A-
– Block connection -B-
Block connections with different types of seal
– Block connection with radial seal -A- (with plastic or metal

guide -B-)
– Block connection with axial seal -C-
Assembling flushing circuit

Audi A1 (8X_) and Audi A2 ⇒ page 113
Audi A1 (GB) ⇒ page 114
Audi Q2, Audi A3, Audi Q3 and Audi TT ⇒ page 114
Audi Q2L e-tron (GAG), from 2019 onwards ⇒ page 116
Audi A3 e-tron ⇒ page 118
Audi 80, Audi 90, Audi Coupé, Audi Cabriolet and Audi ⇒ page 121
A4
Audi A5 Coupé and Sportback, Audi Q5, Audi A5 Cab‐ ⇒ page 124
riolet
Audi Q5 hybrid ⇒ page 126
Audi 100, Audi A6 (4A_, 4B_ and 4F_), Audi allroad ⇒ page 130
and Audi V8
Audi A6 (4G_ or 4X_ for China), Audi A7 (4G_ or 4X_ ⇒ page 131
for China)

Assembling flushing circuit

Audi A6 hybrid, Audi A6 e-tron ⇒ page 132
Audi A6 (4A_ or 48_ for China), Audi A7 (4K_) ⇒ page 136
Audi A7 TFSI e (4K ), from 2018 onwards ⇒ page 137
Audi A8 (4D_, 4E_ and 4H_) ⇒ page 139
Audi A8 hybrid (4H_) ⇒ page 142
Audi A8 (4N) ⇒ page 147
Audi A8 (4N_) TFSI e 2019 ▶ ⇒ page 149
Audi Q7 (4L_) ⇒ page 151
Audi Q7 (4M_), Audi Q8 (4M_) ⇒ page 153
Audi Q7 e-tron (4M_) ⇒ page 155
Audi R8 (42_) ⇒ page 157
Audi R8 (4S_) ⇒ page 158
Audi e-tron (GE_) 2019 ▶ ⇒ page 160
Audi A1 (8X_) 2011 ► and Audi A2

Vehicle Adapters re‐ Adapters required for Other re‐
quired for con‐ connections to reser‐ quire‐
nections to air voir/receiver ments
conditioner com‐
pressor
Audi A1 – Compressor Different versions Expansion
(8X_) manufacturer – Version 1 (receiver valve re‐
2011 ► “Denso”, integrated in con‐ moved and
“Sanden” or denser): No adapt‐ adapter -
“Delphi/ er required; the VAS
Mahle” desiccant bag is re‐ 6338/34-
♦ Low-pres‐ moved from the re‐ or adapter
sure side: ceiver at the con‐ - VAS
adapter - denser and the 6338/39-
VAS opening is sealed (see notes
6338/12- again for flushing. below) fit‐
ted (or old
♦ High-pres‐ – Version 2 (receiver removed
sure side: attached to con‐ expansion
adapter - denser): No adapt‐ valve dril‐
VAS 6338/3- er required; the re‐ led open
or adapter - ceiver is left instal‐ for flushing
VAS 6338/2- led (renewed after and re-in‐
(depending flushing). stalled)
on layout of ⇒ page 92
air condition‐
er compres‐
sor and corre‐
sponding re‐
frigerant line)


conditioner com‐
pressor
Audi A2 – Compressor Reservoir - Restrictor
(8Z_) manufacturer – Screw connection removed,
2001 ► “Denso” at inlet Adapter - pipe con‐
♦ Low-pres‐ VAS 6338/9- nections
sure side: re-assem‐
adapter - – Block connection bled
VAS with axial seal at
6338/12- outlet Adapter -
VAS 6338/10-
♦ High-pres‐
sure side:
adapter -
VAS 6338/2-
Note
♦ Depending on the version of the condenser, the receiver may

be attached to or integrated into the condenser on the Audi
A1/S1. The integrated receiver is fitted with a desiccant car‐
tridge which can be renewed separately. If an attached re‐
ceiver (introduction not yet finalised) is fitted, it must be
renewed after flushing ⇒ Electronic parts catalogue and ⇒
♦ Different versions of air conditioning unit (different heat ex‐
changer, seals, expansion valve etc.), depending on produc‐
tion period and vehicle identification number of Audi A1/S1 ⇒
Electronic parts catalogue . Vehicles with type codes “8X1”
and “8XA” in the vehicle identification number are fitted with
an expansion valve on which the two refrigerant lines are se‐
cured at top ( adapter - VAS 6338/34- is compatible). Vehicles
with the type codes “8XF” and “8XK” in the vehicle identifica‐
tion number are fitted with an expansion valve with two refrig‐
erant lines bolted on at the bottom; the adapter - VAS 6338/39-
is compatible here ⇒ Heating, air conditioner; Rep. gr. 87 ;
Audi Q2, Audi A3, Audi Q3, Audi TT, Audi A1 (GB) 2019 ►
conditioner com‐
pressor
Audi A3 – Compressor Receiver Expansion
(8L_) manufacturer – Block connections valve re‐
1997 ► “Sanden” or with axial seal at in‐ moved and
Audi TT “Zexel / Va‐ let and outlet Adapter -
(8N_) leo” Adapter - VAS VAS
1999 ► ♦ Low-pres‐ 6338/2- (2x re‐ 6338/19-
sure side: quired) fitted (or
adapter - drilled-
VAS 6338/7- open ex‐
pansion
♦ High-pres‐ valve e.g.
sure side: 6N0 820
adapter - 679 C fit‐
VAS 6338/2- ted
⇒
page 92 )


conditioner com‐
pressor
Audi A3 – Compressor Receiver (different ver‐ Expansion
(8P_) manufacturer sions) valve re‐
2004 ► for Audi A3 / – Adapter not re‐ moved and
Audi TT Audi Q3: quired, receiver re‐ adapter -
(8J_) “Sanden”, mains in position VAS
2007 ► “Denso”, 6338/18-
Audi Q3 “Delphi/ – Depending on the (or drilled-
(8U_ / Mahle” or version of the con‐ out expan‐
84_) “Zexel/Valeo” denser, it may be sion valve
2012 ► – Compressor necessary to re‐ e.g.
manufacturer move the desiccant 1K0 820 6
for Audi TT: cartridge from the 79 X) in‐
“Denso”, receiver on the con‐ stalled
“Sanden” or denser before ⇒ page 92
“Delphi/ flushing and to seal
Mahle” the opening again
♦ Low-pres‐ (see note).
sure side:
adapter -
VAS
6338/12-
♦ High-pres‐
sure side:
adapter -
VAS 6338/3-
Audi Q2 – Compressor Receiver (different ver‐

Expansion
(GA_), manufacturer sions) valve re‐
Audi A3 “Denso” or – No adapter re‐ moved and
(8V_/ “Sanden” quired; receiver is
adapter -
85_) ♦ Low-pres‐ not removed (or is
VAS
2013 ► sure side: integrated in con‐
6338/38-
Audi TT adapter - denser). (or drilled-
(FV_) VAS out expan‐
2015 ► 6338/12- – Depending on the sion valve
Audi Q2 version of the con‐ e.g.
(G1_) ♦ High-pres‐ denser, it may be 5Q0 820 6
2019► sure side: necessary to re‐ 79 X) in‐
Audi Q3 adapter - move the desiccant stalled
(F3_/ VAS 6338/3- cartridge from the ⇒ page 92
G2_) ♦ receiver on the con‐
2019 ► denser before
Audi A1 flushing and to seal
(GB ) the opening again
2019 ► (see note).

Note
♦ The design of the receiver on the Audi A3, Audi Q3 and Audi
TT differs depending on the condenser manufacturer. On the
Audi TT (8J_) 2007 ► with a 5-cyl. engine for example, a dif‐
ferent condenser version is installed than in vehicles with 4-
cyl. or 6-cyl. engines. This condenser e.g. has an integrated
receiver. The integrated receiver contains a desiccant car‐
tridge which is currently not always available as a replacement
part. Therefore it may be necessary to renew the complete
condenser after eliminating any faults on vehicles fitted with
this condenser ⇒ Electronic parts catalogue and ⇒ Heating,
cific Workshop Manual).
♦ On vehicles with condensers with an integrated receiver / des‐
are not available as separate replacement parts, the condens‐
er must be renewed (together with integrated desiccant car‐
tridge) after flushing ⇒ Heating, air conditioning; Rep. gr. 87 ;
Audi Q2L e-tron (GAG), from 2019 onwards

conditioner com‐
pressor
Audi ♦ Low-pres‐ – Remove desiccant ♦ Expan‐
Q2L e- sure side: cartridge from re‐ sion
tron adapter - ceiver on condens‐ valve re‐
(GAG), VAS er before flushing moved
from 6338/12- and seal opening and
2019 again (see note). adapter -
on‐ ♦ High-pres‐ VAS
wards sure side: 6338/38-
adapter - (or old,
VAS 6338/3- drilled-
out ex‐
pansion
valve
⇒
page
92 ) in‐
stalled


conditioner com‐
pressor
Adapters/lines ♦ On the
required for con‐ electri‐
nections on elec‐ cally
trically driven air driven
conditioner com‐ air con‐
pressor (for ditioner
flushing air con‐ com‐
ditioner com‐ press‐
pressor) or, the
⇒ page 107 refrig‐
(Flushing electri‐ erant oil
cally driven air is to be
conditioner com‐ re‐
pressor) moved
by
flushing
in the
direc‐
tion of
flow (it
is not
possi‐
ble to
flush in
the op‐
posite
direc‐
tion due
to the
valves
instal‐
led)
♦ For the
flushing
proce‐
dure,
position
the air
condi‐
tioner
com‐
pressor
so that
the
con‐
nection
for the
refrig‐
erant
line on
the
high-
pres‐
sure
side is
as low
down
as pos‐
sible

Note
After flushing, the desiccant cartridge in the receiver on the con‐

denser must be renewed ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit .
Audi A3 e-tron
conditioner com‐
pressor
Audi A3 – Compressor Receiver (different ver‐ ♦ Expansion
(8V_/ manufacturer sions) valve removed
85_) “Denso” or – No adapter re‐ and adapter -
2013 ► “Sanden” quired; receiver is VAS 6338/38-
♦ Low-pres‐ not removed (or is (or drilled-out
sure side: integrated in con‐ expansion
adapter - denser). valve e.g.
VAS – Depending on the 5Q0 820 679 X)
6338/12- version of the con‐ installed
denser, it may be ⇒ page 92
♦ High-pres‐ necessary to re‐
sure side: move the desiccant ♦ Shut-off valves -
adapter - cartridge from the N541- and -
VAS 6338/3- receiver on the con‐ N542- removed
denser before and two shut-off
flushing and to seal valves - VAS
the opening again 6338/42- instal‐
(see note). led instead (see
♦ Shut-off valve - notes below)
VAS 6338/42- Renew shut-off
valves -N541-
and -N542- af‐
ter flushing.
♦ Restrictor in re‐
frigerant line to
heat exchanger
for high-voltage
battery re‐
moved or refrig‐
erant line drilled
open (see notes
below) Renew
after flushing


conditioner com‐
pressor
Adapters / lines ♦ On the
pressor) or, the
(Flushing the erant oil
electrically driv‐ is to be
en air condition‐ re‐
er compressor) moved
by
flushing
in the
direc‐
tion of
flow (it
is not
possi‐
ble to
flush in
the op‐
posite
direc‐
tion due
to the
valves
instal‐
led)
♦ For the
flushing
proce‐
dure,
position
the air
condi‐
tioner
com‐
pressor
so that
the
con‐
nection
for the
refrig‐
erant
line on
the
high-
pres‐
sure
side is
as low
down
as pos‐
sible

Note
♦ The refrigerant circuit on the Audi A3 e-tron is flushed in 2

sections. In the first flushing cycle, the adapter installed for
shut-off valve -N541- is opened and the adapter installed for
shut-off valve -N542- is closed. The refrigerant circuit is flush‐
ed with the evaporator in the conditioning unit. In the second
flushing cycle, the adapter installed for shut-off valve -N541-
is closed and the adapter installed for shut-off valve -N542- is
opened. The refrigerant circuit is flushed with the evaporator
in the heat exchanger for high-voltage battery ⇒ Heating, air
Workshop Manual).
♦ The illustration shows a refrigerant line -A- with a permanently
installed restrictor -B- (without strainer). This refrigerant line
must be drilled open (5.0 mm) with a suitable drill bit in order
to flush the refrigerant circuit (remove restrictor if fitted) and
must be cleaned before it is installed in the flushing circuit.
After flushing, refrigerant line/inserted restrictor must be re‐
newed ⇒ Electronic parts catalogue .
♦ The diameter of the restrictor hole -B- is approx. 0.7 mm. De‐
pending on the version of the refrigerant line, the restrictor is
either only inserted or fixed in position in the refrigerant line. If
it is inserted, there may be a strainer for separating float ele‐
ments, which may block off the restrictor hole.
♦ The design of the receiver on the Audi A3 differs depending
on the manufacturer of the condenser. This condenser e.g.
has an integrated receiver. The integrated receiver contains a
desiccant cartridge which is currently not always available as
a replacement part. Therefore it may be necessary to renew
the complete condenser after eliminating any faults on vehi‐
cles fitted with this condenser ⇒ Electronic parts catalogue

Audi 80, Audi 90, Audi Coupé, Audi Cabriolet and Audi A4
conditioner com‐
pressor
Audi 80 – Compressor Reservoir with differ‐ - Restrictor
(8A_/ manufacturer ent connection ver‐ removed,
8C_), “Zexel / sions pipe con‐
Audi Valeo” (screw ♦ Version 1 nections
Coupé connections) re-assem‐
(8B_), ♦ Low-pres‐ – Screw connection bled
Audi sure side: at inlet Adapter -
Cabrio‐ adapter - VAS 6338/9-
let (8G_) VAG 1785/8-
► 2002 – Screw connection
Audi A4 ♦ High-pres‐ at outlet Adapter -
(8D_) sure side: VAG 1785/8-
1995► adapter -
VAG 1785/7-
– Compressor ♦ Version 2
manufacturer
“Denso” (bloc – Screw connection
k connections at inlet Adapter -
with radial VAS 6338/9-
and axial
seal) – Block connection
♦ Low-pres‐ with axial seal at
sure side: outlet Adapter -
adapter - VAS 6338/10-
VAS
6338/12-
♦ High-pres‐
sure side:
adapter -
VAS 6338/2-
Audi A4 – Compressor Reservoir with differ‐ - Restrictor

(8E_) manufacturer ent connection ver‐ removed,
2001 ► “Denso” (bloc sions pipe con‐
Audi A4 k connections ♦ Version 1 nections
Cabrio‐ with radial re-assem‐
let (8H_) and axial – Block connections bled
2003 ► seal) with axial seal at in‐
♦ Low-pres‐ let and outlet
sure side: ♦ Adapter - VAS
adapter - 6338/10- (2x re‐
VAS quired)
6338/12-
♦ High-pres‐
sure side:
adapter -
VAS 6338/2-


conditioner com‐
pressor
manufacturer
“Denso” (bloc – Block connections
k connections with radial seal at
with radial inlet and outlet
seal) ⇒ Heat‐ ♦ Adapter - VAS
ing, air condi‐ 6338/8- (2x re‐
tioner; Rep. quired)
gr. 87 ; Re‐
frigerant cir‐
cuit (vehicle-
specific
Workshop
Manual)
♦ Low-pres‐
sure side:
adapter -
VAS
6338/12-
♦ High-pres‐
sure side:
adapter -
VAS 6338/3-

(8K_) manufacturer sions) valve re‐
2008 ► “Denso” – Adapter not re‐ moved and
♦ Low-pres‐ quired, receiver re‐ Adapter -
sure side: mains in position VAS
adapter - 6338/36-
VAS – Depending on the (or drilled-
6338/12- version of the con‐ open ex‐
denser, it may be pansion
♦ High-pres‐ necessary to re‐ valve e.g.
sure side: move the desiccant 8K0 820
adapter - cartridge from the 679 A) fit‐
VAS 6338/3- receiver on the con‐ ted
denser before ⇒ page 92
flushing and to seal – Refrig‐
the opening again erant
(see note). line
with in‐
ternal
heat
ex‐
chang‐
er is not
re‐
moved
or is re-
instal‐
led af‐
ter in‐
stalla‐
tion of
adapt‐
er.


conditioner com‐
pressor
Audi A4 – Compressor – No adapter re‐ Expansion
(8W_) manufacturer quired; the dryer is valve re‐
2016 ► “Denso” or removed from the moved and
Audi A4 “Sanden” receiver at the con‐ adapter -
(86_) ♦ Low-pres‐ denser and the VAS
2017 ► sure side: opening is sealed 6338/44-
adapter - off again. installed
VAS (or an old
6338/12- expansion
valve is
♦ High-pres‐ drilled
sure side: open and
adapter - installed as
VAS 6338/3- an adapter
⇒
page 92 )
⇒ Elec‐
tronic parts
catalogue .
Note
♦ The design of the receiver on the Audi A4 (8K_) 2008 > differs
depending on the condenser manufacturer ⇒ Heating, air
Workshop Manual). Depending on the version of the condens‐
er, the receiver may be attached to or integrated into the
condenser. The integrated receiver contains a desiccant car‐
tridge which is currently not always available as a replacement
part. Therefore it may be necessary to renew the condenser
after eliminating any faults on vehicles fitted with this con‐
denser ⇒ Electronic parts catalogue .

Audi A5 Coupé and Sportback, Audi Q5, Audi A5 Cabriolet

quired for con‐ receiver connections quire‐
nections to air ments
conditioner com‐
pressor
Audi A5 – Compressor Receiver (different ver‐
Expansion
Coupé manufacturer sions) valve re‐
and “Denso” – Adapter not re‐ moved and
Sport‐ ♦ Low-pres‐ quired, receiver re‐
adapter -
back sure side: mains in position
VAS
(8T_) adapter - 6338/36-
2008 ► VAS – Depending on the (or drilled-
Audi Q5 6338/12- version of the con‐
open ex‐
(8R_ / denser, it may be
pansion
83_) ♦ High-pres‐ necessary to re‐valve e.g.
2008 ► sure side: move the desiccant
8K0 820
Audi A5 adapter - cartridge from the
679 A) fit‐
Cabrio‐ VAS 6338/3- receiver on the con‐
ted
let (8F_) denser before ⇒ page 92
2009 ► flushing and to seal
– Refrig‐
the opening again erant
(see note). line
with in‐
ternal
heat
ex‐
chang‐
er is not
re‐
moved
or is re-
instal‐
led af‐
ter in‐
stalla‐
tion of
adapt‐
er.
(F5_) manufacturer quired; the dryer is valve re‐
2016 ► “Denso” or removed from the moved and
Audi Q5 “Sanden” receiver at the con‐ adapter -
(FY_) ♦ Low-pres‐ denser and the VAS
2017 ► sure side: opening is sealed 6338/44-
Audi Q5 adapter - off again. installed
(87_) VAS (or an old
2019 6338/12- expansion
valve is
♦ High-pres‐ drilled
sure side: open and
VAS 6338/3- an adapter
⇒
page 92 )
⇒ Elec‐
tronic parts
catalogue .

Note
♦ The receiver version varies on these vehicles depending on

the manufacturer of the condenser ⇒ Heating, air condition‐
shop Manual). Depending on the version of the condenser, the
receiver may be attached to or integrated into the condenser.
The integrated receiver contains a desiccant cartridge which
is currently not always available as a replacement part. There‐
fore it may be necessary to renew the condenser after elimi‐
nating any faults on vehicles fitted with this condenser ⇒

Audi Q5 hybrid
nections to/on air ments
conditioner com‐
pressor
Audi Q5 Adapters re‐ Receiver (different ver‐ Expansion
(8R_) quired for con‐ sions) valve re‐
2011 ► nections to air – Adapter not re‐ moved and
conditioner com‐ quired, receiver re‐ adapter -
pressor mains in position VAS
– Compressor 6338/36-
manufacturer – Depending on the (or drilled-
“Denso” version of the con‐ open ex‐
♦ Low-pres‐ denser, it may be pansion
sure side: necessary to re‐ valve e.g.
adapter - move the desiccant 8K0 820
VAS cartridge from the 679 A) fit‐
6338/12- receiver on the con‐ ted
denser before ⇒ page 92
♦ High-pres‐ flushing and to seal – Refrig‐
sure side: the opening again erant
adapter - (see note). line
VAS 6338/3- with in‐
ternal
heat
ex‐
chang‐
er is not
re‐
moved
or is re-
instal‐
led af‐
ter in‐
stalla‐
tion of
adapt‐
er.


conditioner com‐
pressor
♦ Addi‐ For flushing circuit with There are
tio‐ evaporator in front air various
nally conditioning unit and ways of
for a condenser flushing
vehi‐ ♦ Adapter - VAS the circuit:
cle 6338/5- for sealing ♦ Shut-off
with connection on low- valve -
bat‐ pressure side (to N516-
tery second evaporator removed
cool‐ in battery cooling and
ing module) shut-off
mod‐ valve -
ule ♦ Adapter - VAS VAS
6338/11- for seal‐ 6338/42-
ing connection on installed
high-pressure side in its
(to second evapo‐ place
rator in battery cool‐ (see
ing module) notes
♦ Shut-off valve - below).
VAS 6338/42- or Renew
adapter - VAG shut-off
1785/5- to replace valve -
removed refriger‐ N516-
ant shut-off valve 1 after
for hybrid battery - flushing.
N516- (see notes) ♦ Flushing
the cir‐
cuit in
one or
two
steps
(see
notes)
To flush the evaporator Expansion

in the battery cooling valve in re‐
module and the attach‐ frigerant
ed lines lines to
♦ Adapter - VAS second
6338/3- for con‐ evaporator
necting air condi‐ removed
tioner service sta‐ and adapt‐
tion to connection er - VAS
on low-pressure 6338/36-
side (to second installed
evaporator). (or old ex‐
pansion
♦ Adapter - VAS valve re‐
6338/4- for con‐ moved,
necting air condi‐ drilled
tioner service sta‐ open for
tion to connection flushing
on high-pressure and re-in‐
side (to second stalled
evaporator). ⇒
page 92 ).


conditioner com‐
pressor
pressor) or, the
by
flushing
in the
direc‐
tion of
flow (it
is not
possi‐
ble to
flush in
the op‐
posite
direc‐
tion due
to the
valves
instal‐
led)
♦ For the
flushing
proce‐
dure,
position
the air
condi‐
tioner
com‐
pressor
so that
the
con‐
nection
for the
refrig‐
erant
line on
the
high-
pres‐
sure
side is
as low
down
as pos‐
sible

Note
♦ On vehicles with two evaporators, the refrigerant circuit is

flushed in two / three steps.
♦ Currently the connections on the expansion valves at the
evaporator in the air conditioning unit and at the evaporator in
the battery cooling module are identical; the only differences
are the control characteristics and the refrigerant shut-off
valve 2 for hybrid battery - N517- .
♦ If a refrigerant shut-off valve 1 for hybrid battery - N516- is
installed in the circuit to the evaporator in the air conditioning
unit, the refrigerant circuit cannot be flushed. -N516- forms a
constriction and prevents the refrigerant from flowing through
at an adequate rate. If a shut-off valve - VAS 6338/42- is avail‐
able, install on the -N516- and open. If there is no shut-off valve
- VAS 6338/42- , but two adapters - VAG 1785/5- are available,
the circuit can be flushed with the evaporator in the air condi‐
tioning unit in one work step (re-assemble circuit with one filler
hose and two adapters - VAG 1785/5- ). If there is no shut-off
valve - VAS 6338/42- and only one adapter - VAG 1785/5- ,
the circuit must be flushed in two operations. From the low-
pressure connection on the air conditioner compressor via the
evaporator in the air conditioning unit through to the connec‐
tion for the removed -N516- and from the connection for the
removed -N516- via the condenser to the high-pressure con‐
nection on the air conditioner compressor.
♦ After flushing, the refrigerant shut-off valve 1 for hybrid battery
- N516- must be renewed ⇒ Heating, air conditioning; Rep.
ual).

Audi 100, Audi A6 (4A_, 4B_ and 4F_), Audi allroad and Audi V8
quired for con‐ reservoir connections quire‐
conditioner com‐
pressor
Audi – Compressor Reservoir with differ‐ - Restrictor
100 / manufacturer ent connection ver‐ removed,
Audi A6 “Zexel / sions pipe con‐
(4A_) ► Valeo” (screw ♦ Version 1 nections
1998 connections) re-assem‐
Audi A6 ♦ Low-pres‐ – Screw connection bled
(4B_) sure side: at inlet Adapter -
1998 ► adapter - VAS 6338/9-
Audi all‐ VAG 1785/8-
road – Screw connection
(4B_) ► ♦ High-pres‐ at outlet Adapter -
2005 sure side: VAG 1785/8-
Audi V8 adapter -
(4C_) ► VAG 1785/7-
1994
manufacturer
and axial – Block connection
seal) with axial seal at
♦ Low-pres‐ outlet Adapter -
sure side: VAS 6338/10-
adapter - ♦ Version 3
VAS – Block connections
6338/12- with axial seal at in‐
♦ High-pres‐ let and outlet
sure side: Adapter - VAS
adapter - 6338/10- (2x re‐
VAS 6338/2- quired)
Audi A6 – Compressor – Reservoir with - Restrictor

(4F_) manufacturer block connections removed,
2005 ► “Denso” (bloc with radial seal at pipe con‐
k connections inlet and outlet nections
with radial ♦ Adapter - VAS re-assem‐
seal) 6338/8- (2x re‐ bled
♦ Low-pres‐ quired)
sure side:
adapter -
VAS
6338/12-
♦ High-pres‐
sure side:
adapter -
VAS 6338/3-
Note
The specifications for the Audi A6 (4F_) 2005 ► also apply to the
Audi S6 and Audi RS 6.

Audi A6 (4G_ or 4X_ for China), Audi A7 (4G_ or 4X_ for China)
conditioner com‐
pressor
(4G_ / manufacturer sions) valve re‐
4X_) “Denso” – Adapter not re‐ moved and
2011 ► ♦ Low-pres‐ quired, receiver re‐ adapter -
Audi A7 sure side: mains in position VAS
(4G_ / adapter - 6338/18-
4X_) VAS – Depending on the fitted (or
2011 ► 6338/12- version of the con‐ old expan‐
denser, it may be sion valve
♦ High-pres‐ necessary to re‐ removed,
sure side: move the desiccant drilled
adapter - cartridge from the open for
VAS 6338/3- receiver on the con‐ flushing
denser before and re-in‐
flushing and to seal stalled
the opening again ⇒
(see note). page 92 ).
Note
♦ On certain versions for China the type designation 4X_ is used

instead of 4G_.
shop Manual) and ⇒ Electronic parts catalogue .

Audi A6 hybrid, Audi A6 e-tron

conditioner com‐
pressor
Audi A6 Adapters re‐ Receiver (different ver‐ Expansion
(4G_) quired for con‐ sions) valve re‐
manufacturer A6 hybrid (or old, dril‐
“Denso” (A6 – Depending on the led-out and
hybrid) or version of the con‐ cleaned
“Sanden” (A6 denser, it may be expansion
e-tron) necessary to re‐ valve
♦ Low-pres‐ move the desiccant ⇒
sure side: cartridge from the page 92 )
adapter - receiver on the con‐ installed.
VAS denser before – Refrig‐
6338/12- flushing and to seal erant
the opening again line
♦ High-pres‐ (see note). with in‐
sure side: ternal
adapter - A6 e-tron heat
VAS 6338/3- – Detach receiver ex‐
from bracket, turn it chang‐
through 180 de‐ er is not
grees with refriger‐ re‐
ant lines attached, moved
and secure it so or is re-
that connections instal‐
are at the bottom led af‐
(this ensures that ter in‐
the refrigerant is ex‐ stalla‐
tracted in liquid tion of
form during the adapt‐
flushing process er.
and that the receiv‐
er does not ice up;
refer to note).


conditioner com‐
pressor
♦ Addi‐ For flushing circuit withThere are
tional‐ evaporator in front air various
ly for conditioning unit and ways of
vehi‐ condenser flushing
cles ♦ Adapter - VAS the circuit:
with 6338/5- for sealing ♦ Shut-off
battery connection on low- valve -
cool‐ pressure side (to N516- / -
ing second evaporator V424-
mod‐ in battery cooling removed
ule or module or on heat and
heat exchanger) shut-off
ex‐ valve -
chang‐ ♦ Adapter - VAS VAS
er 6338/11- for seal‐ 6338/42-
ing module or on notes
heat exchanger) below)
♦ Shut-off valve - ♦ Flushing
VAS 6338/42- or the cir‐
adapter - VAG cuit in
1785/5- for installa‐ one or
tion in place of re‐ two
moved shut-off steps
valve -N516- or - (see
V424- (see notes) notes)
For flushing evapora‐ Expansion

tor in battery cooling valve in re‐
module (Audi A6 hy‐ frigerant
brid) or on heat ex‐ lines to
changer for high-volt‐ second
age battery (Audi A6 e- evapora‐
tron) and attached tor / heat
lines exchanger
♦ Adapter - VAS removed
6338/3- for con‐ and adapt‐
necting air condi‐ er -VAS
tioner service sta‐ 6338/36-
tion to connection or -VAS
side (to second (different
evaporator). connec‐
tions, de‐
♦ Adapter - VAS pending on
6338/4- for con‐ version) in‐
necting air condi‐ stalled (or
tioner service sta‐ old expan‐
tion to connection sion valve
on high-pressure removed,
side (to second drilled
evaporator). open for
♦ Shut-off valve - flushing
VAS 6338/42- for and re-in‐
installation in place stalled
of removed shut-off ⇒
valve -N516- / - page 92 ).
V424-


conditioner com‐
pressor
pressor) or, the
by
flushing
in the
direc‐
tion of
flow (it
is not
possi‐
ble to
flush in
the op‐
posite
direc‐
tion due
to the
valves
instal‐
led)
♦ For the
flushing
proce‐
dure,
position
the air
condi‐
tioner
com‐
pressor
so that
the
con‐
nection
for the
refrig‐
erant
line on
the
high-
pres‐
sure
side is
as low
down
as pos‐
sible

Note

instead of 4G_.
♦ On vehicles with two evaporators (one in the air conditioning
unit and one in the battery cooling module or on the heat ex‐
changer for high-voltage battery, e.g. on the Audi A6 e-tron),
the refrigerant circuit is flushed in two/three operations.
♦ The expansion valve on the evaporator in the air conditioning
unit and on the evaporator in the battery cooling module ( re‐
frigerant shut-off valve 2 for hybrid battery - N517- on the A6
hybrid and the expansion valve with refrigerant shut-off valve
2 - N640- on the A6 e-tron) do not always have the same con‐
nections (and if they have the same connections, they also
differ in terms of their characteristic curve) ⇒ Heating, air con‐
Workshop Manual).
♦ If a shut-off valve ( refrigerant shut-off valve 1 for hybrid battery
- N516- on the A6 hybrid / refrigerant shut-off valve - V424- on
the A6 e-tron) is installed in the circuit to the evaporator in the
air conditioning unit, the refrigerant circuit cannot be flushed;
-N516- ( -V424- ) forms a constriction and prevents the refrig‐
erant from flowing through at an adequate rate. If a shut-off
valve - VAS 6338/42- is fitted, install it in place of -N516- ( -
V424- ) and open it. If there is no shut-off valve - VAS 6338/42-
but two adapters - VAG 1785/5- are available, the circuit can
be flushed with the evaporator in the air conditioning unit in
one work step (re-assemble circuit with one filler hose and two
adapters - VAG 1785/5- ). If there is no shut-off valve - VAS
6338/42- and only one adapter - VAG 1785/5- , the circuit must
be flushed in two operations. From the low-pressure connec‐
tion on the air conditioner compressor via the evaporator in the
air conditioning unit through to the connection for the removed
-N516- (the -V424- ) and from the connection for the removed
-N516- (the -V424- ) via the condenser to the high-pressure
connection on the air conditioner compressor.
- N516- ( -V424- ) must be renewed ⇒ Heating, air condition‐
shop Manual).
♦ On the Audi A6 e-tron, the receiver must be renewed after
flushing ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit; Removing and installing receiver .

♦ On the Audi A6 hybrid, it may be sensible to remove the two

refrigerant lines in the engine compartment from the internal
heat exchanger in order to flush the components in the battery
cooling module and the associated refrigerant lines. As a re‐
sult, the adapters and associated refrigerant hoses necessary
for the flushing process can be more easily fitted and removed
♦ On the Audi A6 hybrid, it is possible that the knurled nut for the
filler hose cannot be screwed onto the connection properly if
adapter - VAS 6338/3- is installed on the refrigerant line lead‐
ing to the evaporator in the battery cooling module (depending
on the tolerance at the outlet of the refrigerant pipe leading
from the connection); if this is the case, carefully bend the re‐
frigerant pipe approx. 1 mm to one side.
Audi A6 (4A_ or 48_ for China), Audi A7 (4K_)

conditioner com‐
pressor
(4A_ or manufacturer quired; the dryer is valve re‐
for 48_ “Denso” removed from the moved and
for Chi‐ ♦ Low-pres‐ receiver at the con‐ adapter -
na) sure side: denser and the VAS
2019 ► adapter - opening is sealed 6338/44-
Audi A7 VAS off again. installed
(4K) 6338/12- (or an old
2018 ► connected to expansion
air condition‐ valve is
er service drilled
station and open and
VAS an adapter
6338/48- ⇒
page 92 )
♦ High-pres‐ ⇒ Elec‐
sure side: tronic parts
adapter - catalogue .
VAS 6338/3-
Note
On vehicles with condensers with an integrated receiver / desic‐

cant cartridge which cannot be renewed separately or which are
not available as separate replacement parts, the condenser must
be renewed (together with integrated desiccant cartridge) after
flushing ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit (vehicle-specific Workshop Manual) and ⇒ Electronic parts
catalogue .

Audi A7 (4K_) TFSI e, from 2019 onwards

Vehicle Adapters re‐ Adapters required Other re‐
quired for con‐ for connections to quirements
nections to air receiver / for non-re‐
conditioner com‐ turn and shut-off
pressor valves
(4K_) manufacturer – No adapter re‐ valve re‐
TFSI e, “Sanden” (blo quired; the dryer moved and
from ck connec‐ is removed from adapter -
2019 tions with ra‐ the receiver at VAS
on‐ dial seal) the condenser 6338/44- in‐
wards ♦ Low-pres‐ and the opening stalled (or an
♦ Vehi‐ sure side: is sealed off old expan‐
cle adapter - again. sion valve is
with VAS drilled open
one 6338/12- and installed
evap‐ as an adapt‐
ora‐ ♦ High-pres‐ er
tor sure side: ⇒ page 92 )
adapter - ⇒ Electronic
VAS 6338/3- parts cata‐
logue .
Non-return valves Open or
– 4 non-return close the
valves removed, shut-off
and shut-off valves (in‐
valves stalled in
( -6338/47-1- place of the
and non-return
-6338/47-2- ) valves) ac‐
from shut-off cording to
valve set - the area to
6338/47- instal‐ be cleaned
led ⇒ Heating,
air condition‐
ing; Rep. gr.
87 ; Refriger‐
ant circuit
(vehicle-spe‐
cific Work‐
shop Man‐
ual).
Shut-off valve Open or
– Fitted shut-off close the
valve -V424- re‐ shut-off
moved and shut- valve (instal‐
off valve - VAS led in place
6338/42- fitted of the shut-
instead off valve) ac‐
cording to
the area to
be cleaned.
Renew re‐
frigerant
shut-off
valve - V424-
after flush‐
ing.

Note
♦ On the Audi A7 TFSI e, the refrigerant circuit is flushed in four

steps (flushing cycles) ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit (Cleaning air conditioner refrigerant cir‐
cuit).
♦ To flush the entire refrigerant circuit on the Audi A7 TFSI e, it
is not merely sufficient for the installed shut-off valves to be in
the correct position (open or closed); the electrically activated
valves (in the valve block) must also be in the correct position.
The electrical valves are activated via different routines stored
in the corresponding control unit (e.g. in the thermal manage‐
ment control unit - J1024- ) ⇒ Heating, air conditioning; Rep.
circuit .
♦ To perform the flushing procedure on the Audi A7 TFSI e, the
circuit is separated into multiple sections, which are then flush‐
ed in one flushing cycle each. The circuit is separated by
activation of the electrically activated valves and via the man‐
ual shut-off valves (must be activated manually) ⇒ Heating,
air conditioning; Rep. gr. 87 ; Refrigerant circuit; Cleaning air
conditioner refrigerant circuit , ⇒ Vehicle diagnostic tester
(“Guided Fault Finding”).
♦ The layout of the different flushing circuits for the Audi A7 TFSI
e is described in the vehicle-specific Workshop Manual ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
Cleaning air conditioner refrigerant circuit .
♦ After flushing, the refrigerant receiver at the heat exchanger
for heat pump operation must be renewed ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Refrigerant circuit .
♦ After flushing, the refrigerant shut-off valve - V424- must be
renewed ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit .

Audi A8
conditioner com‐
pressor
Audi A8 – Compressor Reservoir with differ‐ - Restrictor
(4D_) manufacturer ent connection ver‐ removed,
1994 ► “Zexel / sions pipe con‐
Valeo” (screw ♦ Version 1 nections
connections) re-assem‐
♦ Low-pres‐ – Screw connection bled
sure side: at inlet Adapter -
adapter - VAS 6338/9-
VAG 1785/8-
– Screw connection
♦ High-pres‐ at outlet Adapter -
sure side: VAG 1785/8-
adapter -
VAG 1785/7-
manufacturer
and axial – Block connection
seal) with axial seal at
♦ Low-pres‐ outlet Adapter -
sure side: VAS 6338/10-
adapter - ♦ Version 3
VAS – Block connections
6338/12- with axial seal at in‐
♦ High-pres‐ let and outlet
sure side: Adapter - VAS
adapter - 6338/10- (2x re‐
VAS 6338/2- quired)
Audi A8 – Compressor Reservoir - Restrictor

(4E_) manufacturer – Block connections removed,
sure side:
adapter -
VAS
6338/12-
♦ High-pres‐
sure side:
adapter -
VAS 6338/3-


conditioner com‐
pressor
(4H_) manufacturer quired, the desic‐ valve re‐
2010 ► “Denso” (bloc cant bag is re‐ moved and
k connections moved from the adapter -
with radial receiver at the con‐ VAS
seal) denser and the 6338/18-
♦ Low-pres‐ opening sealed off fitted (or
sure side: again for flushing. old expan‐
adapter - sion valve
VAS removed,
6338/12- drilled
open for
♦ High-pres‐ flushing
sure side: and re-in‐
adapter - stalled
VAS 6338/3- ⇒
page 92 ).
♦ Addi‐ For flushing circuit with
tio‐ evaporator in front air
nally conditioning unit
for ♦ Adapter - VAS
vehi‐ 6338/5- for sealing
cles connection (“low-
with pressure side”) to
two second evaporator
evap‐
ora‐ ♦ Adapter - VAS
tors 6338/11- for seal‐
(4- ing connection
zone (“high-pressure
air side”) to second
con‐ evaporator
di‐ • An additional hole
tio‐ may have to be dril‐
ner) led in the adapters
(see below) to be
able to seal the re‐
frigerant lines with
adapters - VAS
6338/5- and -VAS
6338/11- .


conditioner com‐
pressor
For flushing second Expansion
evaporator and corre‐ valve in re‐
sponding pipes frigerant
♦ Adapter - VAS lines to
6338/3- for con‐ second
necting air condi‐ evaporator
tioner service sta‐ removed
tion to connection and adapt‐
on low-pressure er - VAS
side (to second 6338/18-
evaporator). installed
(or old ex‐
♦ Adapter - VAS pansion
6338/4- for con‐ valve re‐
necting air condi‐ moved,
tioner service sta‐ drilled
tion to connection open for
on high-pressure flushing
side (to second and re-in‐
evaporator). stalled
• The adapter may ⇒
have to be re‐ page 92 ).
worked (see below)
to be able to con‐
nect the refrigerant
line to adapter -
VAS 6338/3- .
Note

flushed in two steps.
♦ Currently, the front and rear expansion valves have identical
connections (only the control characteristic curves differ).
Drilling additional hole in adapters - VAS 6338/5- and -VAS

6338/11- .
– Drill hole -A- in addition to hole provided (dimensions in illus‐

tration are given in mm).
Rework adapter - VAS 6338/3- .

– By grinding or filing off material in area -A-, rework the adapter

- VAS 6338/3- such that it can be connected without bending
the refrigerant line (the dimensions in the illustration are given
in mm).

Audi A8 hybrid
conditioner com‐
pressor
Audi A8 Adapters re‐ Receiver (different ver‐ Expansion
(4H_) quired for con‐ sions) valve re‐
manufacturer – Depending on the (or old, dril‐
“Denso” version of the con‐ led-out and
♦ Low-pres‐ denser, it may be cleaned
sure side: necessary to re‐ expansion
adapter - move the desiccant valve
VAS cartridge from the ⇒
6338/12- receiver on the con‐ page 92 )
denser before installed.
♦ High-pres‐ flushing and to seal – Refrig‐
sure side: the opening again erant
adapter - (see note). line
VAS 6338/3- with in‐
ternal
heat
ex‐
chang‐
er is not
re‐
moved
or is re-
instal‐
led af‐
ter in‐
stalla‐
tion of
adapt‐
er.


conditioner com‐
pressor
♦ Addi‐ For flushing circuit with There are
tio‐ evaporator in front air various
nally conditioning unit and ways of
for a condenser flushing
vehi‐ ♦ Adapter - VAS the circuit:
cle 6338/5- for sealing ♦ Shut-off
with connection on low- valve -
bat‐ pressure side (to N516-
tery second evaporator removed
cool‐ in battery cooling and
ing module) shut-off
mod‐ valve -
ule ♦ Adapter - VAS VAS
6338/11- for seal‐ 6338/42-
ing module) notes
♦ Shut-off valve - below).
VAS 6338/42- or Renew
adapter - VAG shut-off
1785/5- to replace valve -
removed refriger‐ N516-
ant shut-off valve 1 after
for hybrid battery - flushing.
N516- (see notes) ♦ Flushing
the cir‐
cuit in
one or
two
steps
(see
notes)
To flush the evaporator Expansion

in the battery cooling valve in re‐
module and the attach‐ frigerant
ed lines lines to
♦ Adapter - VAS second
6338/3- for con‐ evaporator
necting air condi‐ removed
tioner service sta‐ and adapt‐
tion to connection er - VAS
side (to second installed
evaporator). (or old ex‐
pansion
♦ Adapter - VAS valve re‐
6338/4- for con‐ moved,
necting air condi‐ drilled
tioner service sta‐ open for
tion to connection flushing
on high-pressure and re-in‐
side (to second stalled
evaporator). ⇒
page 92 ).


conditioner com‐
pressor
pressor) or, the
by
flushing
in the
direc‐
tion of
flow (it
is not
possi‐
ble to
flush in
the op‐
posite
direc‐
tion due
to the
valves
instal‐
led)
♦ For the
flushing
proce‐
dure,
position
the air
condi‐
tioner
com‐
pressor
so that
the
con‐
nection
for the
refrig‐
erant
line on
the
high-
pres‐
sure
side is
as low
down
as pos‐
sible

Note

flushed in two / three steps.
♦ Currently the expansion valve at the evaporator in the air con‐
ditioning unit and at the evaporator in the battery cooling
module do not have the same connections.
♦ If a refrigerant shut-off valve 1 for hybrid battery - N516- is
installed in the circuit to the evaporator in the air conditioning
unit, the refrigerant circuit cannot be flushed. -N516- forms a
constriction and prevents the refrigerant from flowing through
at an adequate rate. If there is a shut-off valve - VAS 6338/42- ,
install it in place of -N516- and open it; if there is no shut-off
valve - VAS 6338/42- but two adapters - VAG 1785/5- are
available, the circuit can be flushed with the evaporator in the
air conditioning unit in one work step (re-assemble circuit with
one filler hose and two adapters - VAG 1785/5- ). If there is no
shut-off valve - VAS 6338/42- and only one adapter - VAG
1785/5- , the circuit must be flushed in two operations. From
the low-pressure connection on the air conditioner compressor
via the evaporator in the air conditioning unit through to the
connection for the removed -N516- and from the connection
for the removed -N516- via the condenser to the high-pressure
connection on the air conditioner compressor.
- N516- must be renewed ⇒ Heating, air conditioning; Rep.
ual).

Audi A8 (4N)
quired for con‐ connections to receiv‐ quire‐
nections to air er / to second evapo‐ ments
conditioner com‐ rator
pressor
(4N) manufacturer quired; the dryer is valve re‐
2018 ► “Denso” (bloc removed from the moved and
♦ Vehi‐ k connections receiver at the con‐ adapter -
cle with radial denser and the VAS
with seal) opening is sealed 6338/44-
one ♦ Low-pres‐ off again. installed
evap‐ sure side: (or an old
ora‐ adapter - expansion
tor VAS valve is
6338/12- drilled
connected to open and
air condition‐ installed as
er service an adapter
station and ⇒
adapter - page 92 )
VAS ⇒ Elec‐
6338/48- tronic parts
catalogue .
♦ High-pres‐
sure side:
adapter -
VAS 6338/3-
♦ Addi‐ For flushing circuit with Expansion

tio‐ evaporator in front air valve to
nally conditioning unit evaporator
for ♦ Adapter - VAS in front air
vehi‐ 6338/44- and condition‐
cles adapter - VAS ing unit re‐
with 6338/43- (for seal‐ moved and
2 ing refrigerant cir‐ adapter -
evap‐ cuit off from second VAS
ora‐ evaporator) 6338/44-
tors installed.
(4- Expansion
zone valve in re‐
air frigerant
con‐ lines to
di‐ evaporator
tio‐ in rear air
ner) condition‐
ing unit re‐
moved and
adapter -
VAS
6338/43-
installed.


pressor
evaporator and corre‐ valve to
sponding pipes evaporator
♦ Adapter - VAS in front air
6338/44- and condition‐
adapter - VAS ing unit re‐
6338/43- (for seal‐ moved and
ing refrigerant cir‐ adapter -
cuit off from evapo‐ VAS
rator in front air 6338/43-
conditioning unit) installed.
Expansion
valve in re‐
frigerant
lines to
evaporator
in rear air
condition‐
ing unit re‐
moved and
adapter -
VAS
6338/44-
installed.
Note

♦ On vehicles with two evaporators, the refrigerant circuit with
the evaporator in the front air conditioning unit is flushed first.
The refrigerant circuit to the second evaporator (in the rear air
conditioning unit) must be separated so that the refrigerant
flows in the specified direction when the circuit is flushed. This
is done by removing the expansion valve in the refrigerant
lines to the second evaporator and installing the adapter - VAS
6338/43- (closed adapter). After the refrigerant circuit with the
evaporator in the air conditioning unit has been flushed, the
two adapters -VAS 6338/43- and -VAS 6338/44- are renewed
and the refrigerant circuit with the evaporator in the rear air
conditioning unit is flushed.

Audi A8 (4N_) TFSI e 2019 ►

pressor valves
(4N_) manufacturer – No adapter re‐ valve re‐
TFSI e “Sanden” (blo quired; the dryer moved and
2019 ▶ ck connec‐ is removed from adapter -
♦ Vehi‐ tions with ra‐ the receiver at VAS
cle dial seal) the condenser 6338/44- in‐
with ♦ Low-pres‐ and the opening stalled (or an
one sure side: is sealed off old expan‐
evap‐ adapter - again. sion valve is
ora‐ VAS drilled open
tor 6338/12- and installed
as an adapt‐
♦ High-pres‐ er
sure side: ⇒ page 92 )
logue .
valves stalled in
( -6338/47-1- place of the
and non-return
-6338/47-2- ) valves) ac‐
led ⇒ Heating,
air condition‐
ing; Rep. gr.
87 ; Refriger‐
ant circuit
(vehicle-spe‐
cific Work‐
shop Man‐
ual).
cording to
the area to
be cleaned.
Renew re‐
frigerant
shut-off
valve - V424-
after flush‐
ing.

Note
♦ The refrigerant circuit is flushed in 4 operations (flushing cy‐

cles) on the Audi A8 TFSI e ⇒ Heating, air conditioning; Rep.
circuit .
♦ To flush the entire refrigerant circuit on the Audi A8 TFSI e, it
is not merely sufficient for the installed shut-off valves to be in
the correct position (open or closed); the electrically activated
circuit .
♦ To perform the flushing procedure on the Audi A8 TFSI e, the
♦ The layout of the different flushing circuits for the Audi A8 TFSI
e is described in the vehicle-specific Workshop Manual ⇒
circuit .

Audi Q7 (4L_)
pressor
Audi Q7 – Compressor – No adapter re‐ Expansion
(4L_) manufacturer quired; the dryer is valve re‐
♦ Vehi‐ k connections receiver at the con‐ adapter -
cle with radial denser and the VAS
with seal) opening is sealed 6338/17-
one ♦ Low-pres‐ off again. or adapter
evap‐ sure side: - VAS
ora‐ adapter - 6338/33-
tor (2 VAS fitted de‐
zone 6338/12- pending on
air version of
con‐ ♦ High-pres‐ expansion
di‐ sure side: valve (or
tio‐ adapter - drilled-
ner) VAS 6338/3- open ex‐
pansion
valve e.g.
7L0 820
712 A, 7H0
820 679 B
or 7L0 820
679 C fit‐
ted
⇒
page 92 )
⇒ Elec‐
tronic parts
catalogue .
♦ Addi‐ For flushing circuit with
tio‐ evaporator in front air
nally conditioning unit
for ♦ Adapter - VAS
vehi‐ 6338/5- for sealing
cles connection (“low-
with pressure side”) to
2 second evaporator
evap‐
ora‐ ♦ Adapter - VAS
tors 6338/11- for seal‐
(4- ing connection
zone (“high-pressure
air side”) to second
con‐ evaporator
di‐
tio‐
ner)


pressor
evaporator and corre‐ valve at
sponding pipes second
♦ Adapter - VAS evaporator
6338/3- for con‐ removed
necting air condi‐ and Adapt‐
tioner service sta‐ er - VAS
tion to connection 6338/17-
on low-pressure fitted (or
side (to second drilled-
evaporator). open ex‐
pansion
♦ Adapter - VAS valve e.g.
6338/4- for con‐ 7L0 820
necting air condi‐ 712 A fitted
tioner service sta‐ ⇒
tion to connection page 92 )
on high-pressure ⇒ Elec‐
side (to second tronic parts
evaporator). catalogue
Note
On vehicles with two evaporators, the refrigerant circuit is flushed

in two steps.

Audi Q7 (4M_), Audi Q8 (4M_)

pressor
Audi Q7 – Compressor – No adapter re‐ Expansion
(4M_) manufacturer quired; the dryer is valve re‐
Audi Q8 k connections receiver at the con‐ adapter -
(4M_) with radial denser and the VAS
2018 seal) opening is sealed 6338/44-
♦ Vehi‐ ♦ Low-pres‐ off again. installed
cle sure side: (or an old
with adapter - expansion
one VAS valve is
evap‐ 6338/12- drilled
ora‐ open and
tor ♦ High-pres‐ installed as
sure side: an adapter
adapter - ⇒
VAS 6338/3- page 92 )
⇒ Elec‐
tronic parts
catalogue .
♦ Addi‐ For flushing circuit with Expansion
tio‐ evaporator in front air valve to
nally conditioning unit evaporator
for ♦ Adapter - VAS in front air
vehi‐ 6338/44- and condition‐
cles adapter - VAS ing unit re‐
with 6338/43- (for seal‐ moved and
2 ing refrigerant cir‐ adapter -
evap‐ cuit off from second VAS
ora‐ evaporator) 6338/44-
tors installed.
(4- Expansion
zone valve in re‐
air frigerant
con‐ lines to
di‐ evaporator
tio‐ in rear air
ner) condition‐
ing unit re‐
moved and
adapter -
VAS
6338/43-
installed.


pressor
evaporator and corre‐ valve to
sponding pipes evaporator
♦ Adapter - VAS in front air
6338/44- and condition‐
adapter - VAS ing unit re‐
6338/43- (for seal‐ moved and
ing refrigerant cir‐ adapter -
cuit off from evapo‐ VAS
rator in front air 6338/43-
conditioning unit) installed.
Expansion
valve in re‐
frigerant
lines to
evaporator
in rear air
condition‐
ing unit re‐
moved and
adapter -
VAS
6338/44-
installed.
Note

♦ On vehicles with two evaporators, the refrigerant circuit with
the evaporator in the front air conditioning unit is flushed first.
The refrigerant circuit to the second evaporator (in the rear air
conditioning unit) must be separated so that the refrigerant
flows in the specified direction when the circuit is flushed. This
is done by removing the expansion valve in the refrigerant
lines to the second evaporator and installing the adapter - VAS
6338/43- (closed adapter). After the refrigerant circuit with the
evaporator in the air conditioning unit has been flushed, the
two adapters -VAS 6338/43- and -VAS 6338/44- are renewed
and the refrigerant circuit with the evaporator in the rear air
conditioning unit is flushed.

Audi Q7 e-tron (4M_)

pressor valves
Audi – Compressor Receiver Expansion
Q7 e- manufacturer – No adapter re‐ valve re‐
tron “Sanden” (blo quired; the dryer moved and
(4M_) ck connec‐ is removed from adapter -
2016 ► tions with ra‐ the receiver at VAS
♦ Vehi‐ dial seal) the condenser 6338/44- in‐
cle ♦ Low-pres‐ and the opening stalled (or an
with sure side: is sealed off old expan‐
one adapter - again. sion valve is
evap‐ VAS drilled open
ora‐ 6338/12- and installed
tor as an adapt‐
♦ High-pres‐ er
logue .
valves stalled in
( -6338/47-1- place of the
and non-return
-6338/47-2- ) valves) ac‐
led ⇒ Heating,
air condition‐
ing; Rep. gr.
87 ; Refriger‐
ant circuit .
cording to
the area to
be cleaned.
Renew re‐
frigerant
shut-off
valve - V424-
after flush‐
ing.

Note

cles) on the Audi Q7 e-tron ⇒ Heating, air conditioning; Rep.
circuit .
♦ In order for the entire refrigerant circuit to be flushed in the
Audi Q7 e-tron, it is not just the installed shut-off valves that
have to be in the correct position (open or closed). In addition,
the electrically operated valves (in the valve block) also have
to be in the right position. The electrical valves are activated
via different routines stored in the corresponding control unit
(e.g. in the thermal management control unit - J1024- ) ⇒
♦ To perform the flushing procedure on the Audi Q7 e-tron, the
♦ The layout of the different flushing circuits for the Audi Q7 e-
tron is described in the vehicle-specific Workshop Manual ⇒
circuit .

Audi R8 (42_)
quired for con‐ reservoir connections quire‐
conditioner com‐
pressor
Audi R8 – Compressor Reservoir - Restrictor
(42_) manufacturer – Block connections removed,
sure side:
adapter -
VAS
6338/12-
♦ High-pres‐
sure side:
adapter -
VAS 6338/3-
Note
♦ On the Audi R8, the engine must be removed to renew the air
conditioner compressor. However, to flush the refrigerant cir‐
cuit the refrigerant lines can be detached with the air condi‐
tioner compressor installed ⇒ Heating, air conditioning; Rep.
ual). However, it is not advisable to flush the refrigerant circuit
with the air conditioner compressor installed because the
quantity of refrigerant oil cannot be measured while the air
conditioner compressor is installed.
♦ The two condensers are flushed while installed and in the di‐
rection opposite to that of the refrigerant flow.

Audi R8 (4S_)
nections to air er (with dryer) ments
conditioner com‐
pressor
Audi R8 – Compressor Receiver Expansion
(4S_) manufacturer – Block connections valve re‐
2015 ► “Denso” (bloc with radial seal at moved and
k connections inlet and outlet adapter -
with radial ♦ Adapter - VAS VAS
seal) 6338/45- (2x re‐ 6338/36-
♦ Low-pres‐ quired) installed
sure side: (or an old
adapter - expansion
VAS valve is
6338/12- drilled
open and
♦ High-pres‐ installed as
sure side: an adapter
adapter - ⇒
VAS 6338/3- page 92 )
⇒ Elec‐
tronic parts
catalogue .
Receiver
removed
and both
refrigerant
line con‐
nections
connected
to each
other with
two adapt‐
ers - VAS
6338/45-
and a com‐
mercially
available
filler hose
(short ver‐
sion with
5/8" thread
on both
sides)

Note
♦ On the Audi R8, the engine may have to be removed before

renewing the air conditioner compressor (depending on en‐
gine version). However, to flush the refrigerant circuit the
refrigerant lines can be detached with the air conditioner com‐
pressor installed ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit (vehicle-specific Workshop Manual). How‐
ever, it is not advisable to flush the refrigerant circuit with the
air conditioner compressor installed because the quantity of
refrigerant oil cannot be measured while the air conditioner
compressor is installed.
♦ The two condensers are flushed while installed and in the di‐
rection opposite to that of the refrigerant flow.
♦ A short filler hose is also included in the adapter set for refrig‐
erant circuits - VAS 6338/1- .
♦ Although it may be possible to flush the receiver, its large in‐
ternal volume means that it may hold too much liquid refriger‐
ant. When this refrigerant is extracted the reservoir ices up
severely, the refrigerant only evaporates very slowly and the
extraction process takes too long.

Audi e-tron (GE_) 2019 ►

pressor valves
Audi e- – Compressor Receiver Expansion
tron manufacturer – No adapter re‐ valve re‐
(GE_) “Sanden” (blo quired; the dryer moved and
2019 ▶ ck connec‐ is removed from adapter -
tions with ra‐ the receiver at VAS
dial seal) the condenser 6338/44- in‐
♦ Low-pres‐ and the opening stalled (or an
sure side: is sealed off old expan‐
adapter - again. sion valve is
VAS drilled open
6338/12- and installed
as an adapt‐
♦ High-pres‐ er
logue .
valves stalled in
( -6338/47-1- place of the
and non-return
-6338/47-2- ) valves) ac‐
led ⇒ Heating,
air condition‐
ing; Rep. gr.
87 ; Refriger‐
ant circuit .
cording to
the area to
be cleaned.
Renew re‐
frigerant
shut-off
valve - V424-
after flush‐
ing.

Note

cles) on the Audi e-tron ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit; Cleaning air conditioner refrigerant cir‐
cuit .
♦ To flush the entire refrigerant circuit on the Audi e-tron, it is not
merely sufficient for the installed shut-off valves to be in the
correct position (open or closed); the electrically activated
circuit .
♦ To perform the flushing procedure on the Audi e-tron, the cir‐
cuit is separated into multiple sections, which are then flushed
in one flushing cycle each. The circuit is separated by activa‐
tion of the electrically activated valves and via the manual
shut-off valves (must be activated manually) ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit; Cleaning air
♦ The layout of the different flushing circuits for the Audi e-tron
is described in the vehicle-specific Workshop Manual ⇒ Heat‐
ing, air conditioning; Rep. gr. 87 ; Refrigerant circuit; Cleaning
air conditioner refrigerant circuit .
circuit .
5.6 Tracing leaks in refrigerant circuit
WARNING

discharged.

Note
♦ Minor leaks can be detected with e.g. an electronic leak de‐

tector or UV leak detection lamp.
♦ This Workshop Manual describes two ways of tracing leaks in
refrigerant circuits. These procedures have been tested and
lead to a reliable result under the different usage conditions if
they are performed correctly and in accordance with the spe‐
cific complaint.
♦ Numerous systems are available on the market for the detec‐
tion of refrigerant circuit leaks. Not all of these yield unequiv‐
ocal results and, if not employed in the specified manner, may
indicate leaks at various refrigerant circuit components al‐
though these are actually intact. In addition, certain proce‐
dures can lead to damage to components of refrigerant
circuits.
♦ Do not service components that have been identified as leak‐

ing; they must always be renewed.
♦ Leaking refrigerant circuits are not to be filled with refrigerant.
Empty refrigerant circuits are therefore to be evacuated before
filling with refrigerant and checked for leaks in this process
⇒ page 75 .
Caution
♦ Audi objects to the use of chemical substances (sealing

additives) for sealing leaks in refrigerant circuits.
♦ Chemical substances for sealing leaks form deposits in
the refrigerant circuit which will impair operation of the air
conditioning system and lead to failure of the system (and
of the air conditioner service station).
Note
Chemical substances (sealing additives) for sealing leaks in the

refrigerant circuit generally react with the ambient air or the hu‐
midity contained in it. They cause malfunctioning of valves and
other components with which they come into contact on account
of deposits in the refrigerant circuit (and in the air conditioner
service station being used). These deposits cannot be completely
removed from the components affected (even by flushing). There‐
fore the refrigerant circuit can only be serviced by renewing all
components that have come into contact with the chemical sub‐
stances.

⇒ “5.6.1 Tracing leaks in refrigerant circuit using electronic leak

detector (e.g. V.A.G 1796)”, page 163
⇒ “5.6.2 Tracing leaks in refrigerant circuit with leak detection
system VAS 6201”, page 165
⇒ “5.6.3 Locating leaks using vacuum test with air conditioner
service station or nitrogen pressure test”, page 175
5.6.1 Tracing leaks in refrigerant circuit using

electronic leak detector (e.g. V.A.G
1796)
Note
♦ The various refrigerants have a different molecular structure.

The sensors of the electronic leak detectors are matched to
these molecules. If use is made of an electronic leak detector
not specially designed for refrigerant R134a, this will not re‐
spond to refrigerant R134a or only in the event of a high
refrigerant concentration in the vicinity of the leak.
♦ Depending on the design of the air conditioning unit it may be
possible to determine a leak at the evaporator by inserting the
test prod of the leak detector through the connection for glove
compartment cooling into the air conditioning unit or - with the
condensation drain hose detached - by holding the test prod
at the open connection for the condensation drain of the air
conditioning unit.
Leak detection procedure for a refrigerant circuit completely emp‐

ty as a result of leakage:
Caution
Proceed as follows with a completely empty refrigerant circuit

to avoid allowing more refrigerant than is absolutely necessary
for leak detection to escape into the environment:
– Evacuate the refrigerant circuit using the air conditioner serv‐

ice station ⇒ page 75 .
Note
♦ If evacuation already reveals a major leak, this is to be located

and eliminated as described ⇒ page 75 .
♦ Continue as follows if evacuation does not reveal any leakage
or if the leakage is so slight that it is not possible to determine
the leakage location with the vacuum test.
– Pour roughly 100 g of refrigerant into the evacuated refrigerant

circuit and perform leak detection as for a refrigerant circuit
charged with refrigerant ⇒ page 163 .
Performing a leak test on a refrigerant circuit charged with refrig‐
erant:

– Start up leak detector in line with relevant operating instruc‐

tions.
– Always hold tip of test probe beneath suspected leak.
If clicking rate increases or a warning tone sounds (depends on
model), this indicates that the leak has been located (refer to op‐
erating instructions for leak detector).
Note
♦ Refrigerant gas is quickly dispersed by movement of air.

Draughts must therefore be avoided during leak detection.
♦ Refrigerant gas is heavier than air and therefore sinks to a
lower level at the exit location.

5.6.2 Tracing leaks in refrigerant circuit with

leak detection system VAS 6201
Note
♦ Certain leaks are difficult or even impossible to find using an

electronic leak detector. In such cases, the leak detection sys‐
tem VAS 6201 can be used.
♦ Refrigerant circuit leaks result in a loss of refrigerant oil to‐
gether with the refrigerant. This oil generally remains in the
vicinity of the leak location. Adding a small quantity of fluores‐
cent fluid to the refrigerant circuit makes this oil visible under
UV light. The fluid (PAG oil containing an additive which shows
up under UV light) is poured into the refrigerant circuit and is
distributed with the refrigerant oil when the air conditioner is
switched on.
♦ The air conditioner must be operated for at least 60 min. to
distribute the additive through the entire refrigerant circuit (the
air conditioner compressor must be running). Depending on
the extent of the leak, the leakage location may already be‐
come visible under UV light within this period.
♦ The refrigerant oil containing the additive (which shows up un‐
der UV light) can either be poured directly into the open circuit
or pumped in with the circuit charged using the hand pump
VAS 6201/1 (from the leak detection system VAS 6201) via
the service connection on the low-pressure end.
♦ If the UV leak detection additive is applied via the service con‐
nection on the low-pressure end with the refrigerant circuit
charged, a small quantity of UV leak detection additive re‐
mains in the service connection. This is to be carefully re‐
moved so as to avoid subsequent erroneous leak detection.
♦ If a component forming part of a circuit, into which the UV leak
detection additive has been poured, has to be renewed, thor‐
oughly clean joints with other components after assembling
refrigerant circuit. Otherwise, the residual UV leak detection
additive at the joint could be erroneously identified as a leak‐
age location during subsequent leak localisation.
♦ On discharging the refrigerant circuit, refrigerant oil and thus
also UV leak detection additive ingresses into the air condi‐
tioner service station. The refrigerant oil is removed from the
refrigerant in the oil separator of the air conditioner service
station and discharged from the air conditioner service station
via the drain. Do not pour the refrigerant oil drained off back
in. It must be replaced with fresh refrigerant oil.
♦ Observe the following if leak detection fluid has already been
poured into a refrigerant circuit in the course of previous repair
work: Only add new leak detection fluid if refrigerant oil is re‐
newed. If only some of the refrigerant oil has been renewed,
just add the corresponding quantity of leak detection fluid. Af‐
ter replacing 100 ml of refrigerant oil on a vehicle containing
250 ml for example, just add 1 ml (cm3) of UV leak detection
additive.
♦ Certain materials and their compounds (e.g. oxidation prod‐
ucts on aluminium components, anti-corrosion waxes) also
show up under UV light.
♦ Certain types of air conditioner service station allow you to in‐
troduce the UV leak detection additive directly (observe the
information in the operating instructions of the air conditioner
service station).

Proceed as follows with a completely empty refrigerant circuit to

avoid allowing more refrigerant than is absolutely necessary for
leak detection to escape into the environment when localising re‐
frigerant circuit leaks:
– Evacuate the refrigerant circuit using the air conditioner serv‐
ice station ⇒ page 75 .
Note
♦ If evacuation already reveals a major leak, this is to be located

and eliminated as described ⇒ page 175 and ⇒ page 75 .
♦ With the leak detection system - VAS 6201- , it is also possible
to add UV leak detection additive to a charged or open refrig‐
erant circuit ⇒ page 167 .
Continue as follows if evacuation does not reveal any leakage or

if the leakage is so slight that it is not possible to determine the
leakage location on evacuation:
♦ Adding UV leak detection additive to the refrigerant circuit us‐
ing the air conditioner service station ⇒ page 166 .
♦ Adding UV leak detection additive to the refrigerant circuit us‐
ing the leak detection system - VAS 6201- ⇒ page 167 .
Adding UV leak detection additive to the refrigerant circuit using
the air conditioner service station
– Adding UV leak detection additive and the specified quantity
of refrigerant to the refrigerant circuit using the air conditioner
service station ⇒ page 276 .
Note
The quantity of UV leak detection additive to be added to a re‐

frigerant circuit with a refrigerant oil quantity of 100 to 150 cm3
using the hand-operated pump - VAS 6201- of the leak detection
system - VAS 6201- is 2.5 +/- 0.5 cm3. If the quantity of refrigerant
oil in the refrigerant circuit is greater, a corresponding quantity of
UV leak detection additive must be added (e.g. 5.0 +/- 0.5 cm3 for
a refrigerant circuit with a refrigerant oil quantity of 250 cm3).
When adding the UV leak detection additive with an air condi‐
tioner service station, the amount required may differ and atten‐
tion must therefore be paid to the corresponding operating
instructions. For the corresponding refrigerant oil quantity in the
refrigerant circuit, refer to ⇒ page 317 .
Special tools and workshop equipment required

♦ Air conditioner service station with facility for adding UV leak
detection additive to the refrigerant circuit ⇒ Electronic parts
catalogue (Tools; Workshop equipment/tools; Air condition‐
ing/heating).
♦ Approved leak detection additive ⇒ Electronic parts catalogue

♦ Cleaning agent - VAS 6201/3- -3-
♦ UV leak detector lamp - VAS 6201/4- -4-

♦ UV-absorbing safety goggles - VAS 6201/6- -5-
♦ Sticker - VAS 6201/7- -6-
– Affix a sticker next to the service connections to indicate that
UV leak detection additive has been added to this refrigerant
circuit.
– Start up the air conditioner.
Note

♦ Depending on its size and location, it may now take several
days for sufficient refrigerant oil with UV leak detection additive
to emerge to identify the leakage point clearly.
– Use a UV lamp VAS 6196/4 to locate the refrigerant circuit leak

⇒ page 173 .
Adding UV leak detection additive to the refrigerant circuit using
the leak detection system - VAS 6201-
Special tools and workshop equipment required
♦ Leak detection system - VAS 6201-

The VAS 6201 leak detection system includes the following tools
⇒ Electronic parts catalogue (Tools; Workshop equipment/tools;
Air conditioning/heating).
1- Hand pump with low-pressure service hose, service cou‐
pling and non-return valve - VAS 6201/1-
2- Cartridge - VAS 6201/2- (with UV leak detection additive)
3- Cleaning solution - VAS 6201/3-
4- UV leak detection lamp - VAS 6201/4-
5- UV-absorbing eye protection - VAS 6201/6-
6- Sticker - VAS 6201/7-
7- Tube
VAS 6201/8
8- Protective gloves - VAS 6201/9-
Note
♦ The following procedure describes the addition of UV leak de‐

tection additive using the hand pump - VAS 6201- . Observe
the corresponding operating instructions if the UV leak detec‐
tion additive is to be added to the refrigerant circuit using a
different tool (e.g. an air conditioner service station).
♦ The quantity of UV leak detection additive to be added to a
refrigerant circuit with a refrigerant oil quantity of 100 to 150
cm3 using the hand-operated pump - VAS 6201- is indicated
in the following (2.5 +/- 0.5 cm3). If the quantity of refrigerant
oil in the refrigerant circuit is greater, a corresponding quantity
of UV leak detection additive must be added (e.g.
5.0 +/- 0.5 cm3 for a refrigerant circuit with a refrigerant oil
quantity of 250 cm3). For the corresponding refrigerant oil
quantity in the refrigerant circuit, refer to ⇒ page 317 .
♦ Observe the quantity of UV leak detection additive given in the
corresponding operating instructions if the UV leak detection
additive is to be added to the refrigerant circuit using a different
tool (e.g. an air conditioner service station).
Adding UV leak detection additive with refrigerant circuit empty

The cartridge -A- contains 15.4 ml of UV leak detection additive
(one unit -B- corresponds to 2.5 ml).

– Assemble hand pump - VAS 6201- , item -1- with cartridge,

item -2- -VAS 6201/2- .
– Insert filler tube - VAS 6201/8- ( ⇒ page 168 item -7-) in hand
pump.
– Open hand pump service valve.
Note
♦ When the refrigerant circuit is empty, the UV leak detection

additive can be added to the circuit via a service connection
or an open connection.
♦ If the refrigerant circuit is empty, it may be better to add the
UV leak detection additive by way of a joint (e.g. if a joint has
already been unfastened). In this way, no UV leak detection
additive is left in the service connection and the connection
does not have to be cleaned.
♦ Addition of UV leak detection additive to the refrigerant circuit

by way of a service connection ⇒ page 171 .
♦ Addition of UV leak detection additive to the refrigerant circuit
by way of an open connection ⇒ page 170 .

Addition of UV leak detection additive to the refrigerant circuit by

way of an open connection.
– Open the refrigerant circuit at a readily accessible connection.
– Cover the surrounding area with sheeting or absorbent paper.
– Hold filler tube upwards.
– Screw in the toggle of the hand pump until the UV leak detec‐
tion additive emerges from the tube.
– Add 2.5 +/-0.5 ml (millilitre = cm3) of UV leak detection additive
to the refrigerant circuit (for a refrigerant circuit with a refrig‐
erant oil quantity of 100 to 150 cm3).
Note
Observe the following if UV leak detection fluid has already been

work: Only add new UV leak detection fluid if refrigerant oil is re‐
newed. If only some of the refrigerant oil has been renewed, only
add the corresponding quantity of UV leak detection additive. Af‐
ter replacing 100 ml of refrigerant oil on a vehicle containing 250
ml for example, just add 2 ml (cm3) of UV leak detection additive.
– Renew O-ring at open connection.

– Assemble refrigerant circuit.
– Affix a sticker next to the service connections to indicate that
leak detection fluid has been added to this refrigerant circuit.
Note

♦ Depending on its magnitude and location, it may now take
several days for sufficient refrigerant oil with additive to
emerge to clearly localise the leakage point.

⇒ page 173 .

Adding UV leak detection additive with refrigerant circuit charged
Note
♦ Observe the following if leak detection fluid has already been

work: Only add new leak detection fluid if refrigerant oil is re‐
newed. If only some of the refrigerant oil has been renewed,
just add the corresponding quantity of leak detection fluid. Af‐
ter replacing 100 ml of refrigerant oil on a vehicle containing
250 ml for example, just add 1 ml (cm3) of UV leak detection
additive.
♦ A small quantity of UV leak detection additive remains in the
service connection. This is to be carefully removed so as to
avoid subsequent erroneous leak detection.
The cartridge -A- contains 15.4 ml of UV leak detection additive

(one unit -B- corresponds to 2.5 ml).

– Detach cap from service connection on low-pressure side of
refrigerant circuit.
– Assemble hand pump - VAS 6201- , item -1- with cartridge,
item -2- -VAS 6201/2- .
– Insert the tube - VAS 6201/8- ( ⇒ page 168 item -7-) in the
service coupling and open the service coupling by screwing in
the handwheel. Hold the hose upwards and screw in the toggle
of the hand pump until the UV leak detection additive starts to
emerge from the tube.
Note
Make sure hand pump hose is completely filled with refrigerant.
– Close service coupling and remove filler tube from locking

mechanism.

– Cover area around service connection on vehicle with sheet‐

ing or absorbent paper.
– Connect filler unit to refrigerant circuit service connection on
vehicle.
– Open service connection by screwing in handwheel.
– Screw in toggle of hand-operated pump and add 2.5 +/-0.5 ml
(millilitre = cm3) of UV leak detection additive to the refrigerant
circuit (for a refrigerant circuit with a refrigerant oil quantity of
100 to 150 cm3).

– Detach filler unit from service connection.

– Use absorbent paper, for example, to remove the residual UV
leak detection additive from the service connection.
– Seal service connection with cap.
– If necessary, use cleaning solution to clean area around serv‐
ice connection.
– Affix sticker next to service connections to indicate that leak
detection fluid has been added to the refrigerant circuit.
Note

♦ Depending on its magnitude and location, it may now take
several days for sufficient refrigerant oil with additive to
emerge to clearly localise the leakage point.

⇒ page 173 .
Finding leaks in refrigerant circuit with UV lamp VAS 6196/4
WARNING
Never look into UV lamp.

Never point UV lamp at other people.

Note
♦ The air conditioner must be operated for at least 60 min. after

adding the UV leak detection additive so that the additive is
distributed through the entire refrigerant circuit (the air condi‐
tioner compressor must be running). Depending on the extent
of the leak, the leakage location may already become visible
under UV light within this period.
♦ Depending on its magnitude and location, it may take several
days for sufficient refrigerant oil with additive to emerge to
clearly localise the leakage point.
♦ In the event of leaks at the evaporator, the additive may be
washed out with the condensation and emerge via the con‐
densation drain. As considerable work is required on most
vehicles to gain access to the evaporator, a check e.g. at the
condensation drain can provide an indication of evaporator
leakage. However, this requires the additive to have been in
the refrigerant circuit for a lengthy period (several days).
♦ The safety goggles are not only designed to provide eye pro‐
tection. They also make the UV leak detection additive more
readily visible under UV light.
♦ Depending on the accessibility of various parts of the refriger‐
ant circuit, it may be necessary to remove certain vehicle
components (e.g. the bumper or air cleaner).
♦ Certain parts of the refrigerant circuit are only supplied with a
small quantity of refrigerant oil in the course of air conditioner
operation (e.g. top-mounted cap of receiver attached to con‐
denser on Audi A8 2010 >). In the event of leakage at such
locations, it may take longer for a sufficient amount of refrig‐
erant with refrigerant oil and additive which shows up under
ultraviolet light to emerge for leak detection. It may therefore
be advisable to use an electronic leak detector to search for
leaks in these areas
⇒ “5.6.1 Tracing leaks in refrigerant circuit using electronic
leak detector (e.g. V.A.G 1796)”, page 163 .
♦ .
– Move vehicle to a poorly lit area of the workshop (daylight or

bright artificial lighting diminishes the effect of the UV light).
– Check the accessibility of the various parts of the refrigerant
circuit and remove any components in the surrounding area
which prevent a clear view of the refrigerant circuit compo‐
nents (e.g. noise insulation and bumper).
– Wear safety goggles to protect the eyes.
– Connect the UV lamp to a 12 V battery (vehicle battery). Take
care to ensure correct polarity of connections.
– Switch on UV lamp and illuminate components of refrigerant
circuit. Locations at which leakage has caused refrigerant, re‐
frigerant oil and therefore also UV leak detection additive to
emerge are lit up under UV light (fluorescent).

5.6.3 Locating leaks using vacuum test with

air conditioner service station or nitro‐
gen pressure test
Vehicles with high-voltage system (hybrid vehicles)
All vehicles
♦ Establishing leaks by way of vacuum test with air conditioner
service station or nitrogen pressure test
⇒ “5.3.4 Evacuating refrigerant circuit with air conditioner serv‐
ice station”, page 75
Note
♦ Minor refrigerant circuit leaks (loss amounting to less than 100

g of refrigerant per year) can generally not be established by
way of the vacuum test or nitrogen pressure test. The quantity
of air ingressing or nitrogen escaping is not sufficient to be
audible.
♦ Depending on the ambient conditions (ambient noise, leakage
location etc.), it may also not always be possible to establish
refrigerant circuit leaks involving a loss of more than 100 g of
refrigerant per year using the vacuum or nitrogen pressure
test. The quantity of air entering or the quantity of nitrogen
escaping may not be sufficient to produce any noise which
would make it possible to identify the location of the leak.
♦ Depending on the ambient conditions, it may be possible to
detect major refrigerant circuit leaks (e.g. caused by flying
stones at the condenser, loss of refrigerant more than 100 g
per day) from the noise occurring at the fault location during
the vacuum or nitrogen pressure test for example
⇒ “5.3.4 Evacuating refrigerant circuit with air conditioner serv‐
ice station”, page 75 .

6 Problems with refrigerant circuit

⇒ “6.1 Possible complaints about refrigerant circuit”, page 176
6.1 Possible complaints about refrigerant

circuit
⇒ “6.1.1 Test requirements:”, page 176
⇒ “6.1.2 Possible complaints”, page 176
6.1.1 Test requirements:

• Electrical system, vacuum system and air duct fault-finding
has not revealed any faults ⇒ Vehicle diagnostic tester (“Self-
diagnosis” or “Guided Fault Finding” function for air condition‐
er), ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations and ⇒ Heating, air conditioning or ⇒ Air condition‐
ing .
• Air conditioner self-diagnosis/Guided Fault Finding with the ⇒
Vehicle diagnostic tester has not revealed any faults, no com‐
pressor shut-off criteria displayed in measured value block
(vehicles with “air conditioner” self-diagnosis only) ⇒ Heating,
air conditioning or ⇒ Air conditioning or “Guided Fault Finding”
function ⇒ Vehicle diagnostic tester .
6.1.2 Possible complaints
Note
♦ For all complaints marked *, refer to ⇒ page 183 “Checking

pressures”.
♦ If problems are only encountered at one evaporator on vehi‐
cles fitted with two evaporators, also check the pressures in
♦ Observe test requirements ⇒ page 176 .
Vehicles without high-voltage system

♦ The cooling system has failed completely.*
♦ Insufficient cooling output at all vehicle speeds/engine
speeds.*
♦ No or insufficient cooling after driving a few miles. *
♦ No or insufficient cooling at one or via both evaporators (on
vehicles with two air conditioning units). *
♦ Air conditioner compressor, air conditioning system magnetic
clutch - N25- or air conditioner compressor regulating valve -
N280- are shut off by a pressure switch (e.g. -F73-, -F118-, -
F129- or by the operating and display unit for front air
conditioning system - E87- or the Climatronic control unit -
J255- ) on account of excessive or inadequate pressure. * ⇒
Heating, air conditioner; Rep. gr. 87 ; Refrigerant circuit (ve‐
♦ Fresh air supply is not available or is reduced significantly after
driving several miles (evaporator iced up). *
Vehicles with high-voltage system
♦ The cooling system has failed completely.*
♦ Insufficient cooling output at all vehicle speeds/air conditioner
compressor speeds.*

♦ No or insufficient cooling after driving a few miles. *

♦ No or insufficient cooling at evaporator or at one of the heat
exchangers (e.g. heat exchanger for high-voltage battery). *
⇒ Heating, air conditioner; Rep. gr. 87 ; Refrigerant circuit
♦ No or insufficient heating output at heat exchanger for heat
pump operation (e.g. on the Audi Q7 e-tron)* ⇒ Heating, air
Workshop Manual).
♦ The electrical air conditioner compressor - V470- is switched
off by a control unit (e.g. operating and display unit for front air
conditioning system - E87- , Climatronic control unit - J255- or
thermal management control unit - J1024- ) if the pressure is
too high or too low. * ⇒ Vehicle diagnostic tester in “Guided
Fault Finding” mode
♦ Fresh air supply is not available or is reduced significantly after
driving several miles (evaporator iced up). *
All vehicles
In addition, the following problems may occur:
The air conditioner compressor is noisy
– Re-tighten the bolts for the air conditioner compressor and the
compressor holder using a torque wrench.
– Check routing of refrigerant pipes; they must not touch other
components and must not be subject to strain (align if neces‐
sary).
Noise (refrigerant hammer) occurring immediately after switching
on the air conditioner and/or when cornering or braking
– Discharge, evacuate and re-charge refrigerant circuit (too
much refrigerant in circuit).
Note
Too much refrigerant oil in the circuit may also result in this prob‐
lem (no adjustment of refrigerant oil quantity, for example, when
renewing compressor).
Water sprays out of the vents (in the dash panel or footwell) al‐
though the air conditioning system is otherwise functioning prop‐
erly
– Check proper routing of condensation drain; it must not be
crushed or kinked.
– Check the condensation drain valve; it must not be gummed
up with wax or underseal and must close properly.
– Check the plenum chamber cover; it must be undamaged and
be installed correctly (no water must flow into the evaporator).
– Check water drains in plenum chamber; they must not be
blocked (e.g. by leaves).
6. Problems with refrigerant circuit 177

7 Connecting air conditioner service

station
♦ If work on high-voltage system components is necessary, de-
energise high-voltage system ⇒ Rep. gr. 93 ; De-energising
high-voltage system or ⇒ Electrical system; Rep. gr. 93 ; De-
energising high-voltage system .
Note
When working on the refrigerant circuit using the air conditioner

service station, the high-voltage system does not usually have to
be de-energised.

⇒ “7.1 Connecting air conditioner service station - vehicles with a
connection on the low-pressure and high-pressure side of the re‐
frigerant circuit”, page 178
⇒ “7.2 Connecting air conditioner service station - vehicles with
no connection on the low-pressure side of the refrigerant circuit”,
page 179
7.1 Connecting air conditioner service sta‐

tion - vehicles with a connection on the
low-pressure and high-pressure side of
the refrigerant circuit
Connecting air conditioner service station for measuring and test‐
ing
– Connect quick-release coupling adapter to filler hoses of air
conditioner service station (handwheels not screwed in/hand
shut-off valve not open).
– Switch on the air conditioner service station and evacuate the
filler hoses (only necessary if there is air in the filler hoses).
– Switch on air conditioner service station.
– Unscrew sealing caps from service connections (with valve).
– Connect air conditioner service station to vehicle refrigerant
circuit via service connections with quick-release coupling
adapters.
– Only screw in the handwheel of the quick-release coupling
adapters to the extent required to reliably open the valves at
the refrigerant circuit connection (observe pressure gauge, do
not open valves further than necessary).


tioner functions (e.g. on the Audi Q7 e-tron):
Note
On vehicles with the “heat pump” and/or “high-voltage battery

connection on the high-pressure side in all air conditioner oper‐
ating modes. On these vehicles, the pressure in the refrigerant
circuit on the high-pressure side can only be measured via the
pressure/temperature senders installed in the refrigerant circuit
(depending on the air conditioner operating mode) ⇒ Heating, air
Finding”).
To check the various functions of these air conditioners:

– On the vehicle diagnostic tester, select the corresponding
function (“passenger compartment cooling”, “heat pump op‐
eration” or “high-voltage battery cooling”) and perform the
function according to requirements ⇒ Vehicle diagnostic tester
in “Guided Fault Finding” mode.
– On the vehicle diagnostic tester, select and read out the meas‐
urements from the various pressure/temperature senders in‐
stalled in the refrigerant circuit ⇒ Vehicle diagnostic tester in
All vehicles
– Perform planned tests and measurements.
7.2 Connecting air conditioner service sta‐

tion - vehicles with no connection on the
low-pressure side of the refrigerant cir‐
cuit
On the following vehicles, no service connection is provided for
the air conditioner service station on the low-pressure side of the
refrigerant circuit. Adapters are required for connecting the air
conditioner service station to the refrigerant circuit of these vehi‐
cles.
♦ Audi 80, Audi Cabriolet, Audi Coupé
♦ Audi A4 up to 07/96
♦ Audi 100 / Audi A6 up to 03/97
♦ Audi A8 up to 11/97
Note
On vehicles without a connection or with an inaccessible connec‐

tion at the air conditioner compressor, remove the low pressure
switch for air conditioning system - F73- (bridge contacts in con‐
nector for low pressure switch for air conditioning system - F73- )
and screw adapter onto this connection ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific Workshop
Manual).
7. Connecting air conditioner service station 179

Note
♦ The tools listed below are commercially available or can be

obtained from the regional sales centre or importer.
♦ Should it be necessary to measure pressures at switch con‐
nections on high-pressure side, use adapter from adapter set
for refrigerant circuit - V.A.G 1785/9- and proceed in the same
manner.
⇒ “7.2.1 Connecting air conditioner service station to refrigerant

circuit with adapter set for refrigerant circuit V.A.G 1786 ”,
page 180
⇒ “7.2.2 Connecting air conditioner service station to refrigerant
circuit with adapter V.A.G 1785/10”, page 181
⇒ “7.2.3 Connecting air conditioner service station for measuring
and testing”, page 181

tion to refrigerant circuit with adapter set
for refrigerant circuit - V.A.G 1786-
A - Connection with valve (small valve core) at low-pressure side
of refrigerant circuit
B - Adapter with union nut - V.A.G 1786/1-
C - Commercially available filler hose (short version with 5/8"
thread on each end)
D - Adapter with service connection - V.A.G 1786/2- (for connec‐
tion of quick-release coupling of air conditioner service station
-E-)
Note
♦ Assemble adapter and filler hose as shown and start by con‐

necting to connection with valve -A-.
♦ The adapter with union nut - V.A.G 1786/1- is only to be used
at connections with a “small” valve core (standard for connec‐
tion with valve for low-pressure switch for air conditioning
system - F73- and also gradually introduced as of 10.94 at the
air conditioner compressor).
♦ Instead of adapter with union nut - V.A.G 1786/1- , you can
also use adapter - V.A.G 1785/10- (remove valve from adapter
- V.A.G 1785/10- or install valve opener in filler hose).


tion to refrigerant circuit with adapter
V.A.G 1785/10
– Unscrew the sealing cap from the connection with valve -A-
(at the air conditioner compressor).
– Attach O-ring -B- to connection (8.9 mm; 1.8 mm).
– Screw adapter V.A.G 1785/10 -C- onto connection -B-.
– Install valve opener -D- with appropriate seal in filler hose
connection.
Note
♦ The type of valve opener -D- and seals required depends on

the filler hose used (specific to manufacturer).
♦ The quick-release coupling adapter is not required for con‐
nection on the low-pressure side of Audi vehicles.
♦ Screw filler hose -E- (to air conditioner service station) onto
adapter - V.A.G 1785/10- .
Note
To minimise the amount of air and moisture entering the filler ho‐
ses and thus into the refrigerant circuit, the filler hoses should be
connected as illustrated.
A - Filler hose to air conditioner service station

B - Hand shut-off valve
C - Filler hose (short version) with valve opener for connection to
adapter -D-
D - Adapter - V.A.G 1785/10-
E - Filler hose (short version) with quick-release coupling adapter
(for vehicles with quick-release coupling adapter on low-pressure
side)

tion for measuring and testing
– Assemble adapter set and screw onto connection on low-
pressure side.
– Connect quick-release coupling adapter to filler hoses of air
conditioner service station (handwheels not screwed in/hand
shut-off valve not open).
– Switch on air conditioner service station and evacuate filler
hoses (only necessary if there is air in the filler hoses).
7. Connecting air conditioner service station 181

– Switch off air conditioner service station.

– Unscrew the sealing cap from the service connection or the
connection with valve (or remove the low-pressure switch and
jumper the corresponding electrical connections).
– Connect air conditioner service station to vehicle refrigerant
circuit via service connections with quick-release coupling
adapters.
– Only screw in the handwheel of the quick-release coupling
adapters to the extent required to reliably open the valve at the
refrigerant circuit connection (observe pressure gauge, do not
open valve too far).

8 Checking pressures
⇒ “8.1 Checking pressures in refrigerant circuit with air conditioner
service station (with ignition switched off)”, page 183
⇒ “8.2 Checking pressures - vehicles with restrictor and reservoir
(with internally regulated air conditioner compressor)”,
page 189
⇒ “8.3 Checking pressures - vehicles with expansion valve and
receiver (with internally regulated air conditioner compressor)”,
page 194
⇒ “8.4 Checking pressures - vehicles with restrictor, reservoir and
air conditioner compressor regulating valve N280 (with externally
regulated air conditioner compressor)”, page 200
⇒ “8.5 Checking pressures - vehicles with expansion valve, re‐
ceiver and air conditioner compressor regulating valve N280 (with
externally regulated air conditioner compressor)”, page 207
⇒ “8.6 Checking pressures - vehicles with electrically driven air
conditioner compressor (vehicles with high-voltage system)”,
page 218
8.1 Checking pressures in refrigerant circuit

with air conditioner service station (with
ignition switched off)
Note
♦ All test requirements marked with an * are vehicle-specific and

are described in the Workshop Manual for the relevant vehicle.
♦ Check cooling output.*
♦ Connections with valve and service connections for measuring
and testing ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
Under certain operating conditions, residual moisture in the cool‐

ant circuit may lead to the formation of ice at the air conditioner
compressor regulating valve. Such ice formation impedes the
control of the air conditioner compressor. The evaporator is
cooled down too much and ices up. An iced-up evaporator may
cause the following problems:
♦ The air conditioning system fails repeatedly or sporadically (no
cooling/heating output) after extended driving; after the vehicle
has been stopped, the air conditioner functions properly again
(after a short wait).
♦ Misting up of the windows (front windscreen, side windows
and / or rear windscreen) on the inside after a long journey;
8. Checking pressures 183

the windows are initially not cleared even by pressing the De-
frost button; the air conditioner functions properly again after
a short delay following engine shut-off.
Remedy:
– In the case of vehicles as of Model Year 2001 and an air con‐
ditioner compressor with air conditioner compressor regulat‐
ing valve - N280- , check the measured value of the evaporator
output temperature sender - G263- (by way of the “Reading
measured value block” function). If the measured value of the
sender is too low under the usage conditions outlined by the
customer (at ambient temperatures above 0 °C, below 0 °C for
a lengthy period although -N280- is not being activated) or too
high (above approx. 10 °C although air conditioner is operating
properly), The evaporator may ice up due to the incorrect
measured value ⇒ Vehicle diagnostic tester (“self-diagnosis”
or “Guided Fault Finding” function for air conditioner) and ⇒
– On vehicles without an evaporator output temperature sender
- G263- , use for example footwell vent temperature sender -
G192- to check vent temperature under operating conditions
described by customer in the following settings: "Lo tempera‐
ture" for driver and passenger side, 4 or 5 bars for fresh air
blower speed, air outlet to footwell and fresh-air mode. If
measured value of sender is too low (at ambient temperature
above 0°C, colder than 0°C for lengthy period).
– Check refrigerant line between evaporator and reservoir (thick
line, low-pressure side) with engine running. If this line is se‐
verely iced up when the problem occurs (thin layer of ice is
permissible), this also indicates that evaporator temperature
is too low.
– Discharge refrigerant circuit, renew reservoir or receiver with
dryer and then evacuate refrigerant circuit for at least 3 hours.
⇒ “8.1.1 Test requirements”, page 184
⇒ “8.1.2 Checking pressures ”, page 186
8.1.1 Test requirements
Note
This section describes the test requirements for a vehicle with a

mechanically driven air conditioner compressor as an example.
These requirements differ on vehicles with high-voltage system
(e.g. Audi A3 e-tron, Audi Q7 e-tron) or with additional air condi‐
tioner functions (e.g. Audi Q7 e-tron). On these vehicles, note the
corresponding information in the Workshop Manual and in Guided
Fault Finding ⇒ Heating, air conditioning; Rep. gr. 00 ; Repair
instructions; Checking cooling output (vehicle-specific Workshop
Manual) and ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
mode.
• Radiator and condenser clean (clean if necessary)

• Thermal insulation at expansion valve OK and properly instal‐
led*
• Poly V-belt OK and properly tensioned. / belts for air condi‐
tioner compressor and alternator OK and properly tensioned.*
• All air ducts, covers and seals OK and properly installed
• No faults detected during fault-finding on electrical system and
vacuum system* ⇒ Vehicle diagnostic tester (“self-diagnosis”


• No fault detected during air conditioner self-diagnosis (with
engine running and air conditioning system switched on), no
compressor shutoff criteria displayed in measured value block
(vehicles with “air conditioning system” self-diagnosis only).*
⇒ Vehicle diagnostic tester (“self-diagnosis” or “Guided Fault
Finding” function for air conditioner) and ⇒ Heating, air con‐
Workshop Manual).
• Check whether the various pressure/temperature senders and
temperature sensors installed in the refrigerant circuit deliver
plausible measured values during operation of the air condi‐
tioner ⇒ Vehicle diagnostic tester (“Guided Fault Finding”) and
⇒ Heating, air conditioning; Rep. gr. 87 ; Overview of fitting
locations - air conditioner . If no fault is found, extract refriger‐
ant.
• Air flow through dust and pollen filter not impeded by dirt*
• Air conditioning unit not drawing in secondary air at maximum
fresh air blower speed; evaporator and heater not drawing in
secondary air at maximum fresh air blower speed*
• Air flaps in air conditioning unit, heater and evaporator reach
end position*
• Fresh-air intake ducts beneath bonnet and in passenger com‐
partment as well as corresponding water drain valves OK* ⇒
Heating, air conditioning; Rep. gr. 87 ; Air ducting (vehicle-
• Engine at operating temperature
• Vehicle not exposed to sunlight ⇒ Heating, air conditioning;
Rep. gr. 00 ; Repair instructions; Checking cooling output
(vehicle-specific Workshop Manual)
• Ambient temperature above 15 °C
• All dash panel vents open
– Start engine.
Setting on the air conditioning system control unit, e.g. on the op‐
erating and display unit for front air conditioning system - E87- or
the Climatronic control unit - J255- (and the rear Climatronic op‐
erating and display unit - E265- on vehicles with two air condi‐
tioning units):
– Select “Auto” mode (air conditioner compressor switched on).
– Set “LO” temperature for driver and front passenger side (and
rear left and right of passenger compartment in vehicles with
two air conditioning units).
Settings on heater controls:
– Press A/C button and "Rec" or recirculated air button.
– Turn the rotary temperature control towards the “cold” stop.
– Set rotary fresh air blower control to “4”.
Subsequently, the following system test requirements should be
met:
• Radiator fan - V7- (and radiator fan 2 - V177- if fitted) must be
running (at least at speed 1).*

Note
With some versions, the fan is not switched on until the pressure
in the refrigerant circuit has exceeded a specified value.
• Fresh air blower - V2- (and rear fresh air blower - V80- on
vehicles with two air conditioning units) run(s) at maximum
speed.
• Air recirculation flap/fresh air flap is in “Air recirculation mode”
position (air flow flap is closed and air recirculation flap opened
within 1 min. after the vehicle is started).*
• Coolant shut-off valve closed.*
• Valves of pump valve unit closed and no coolant circulation
pump delivery*
• Air conditioner compressor is actually driven ( air conditioning
system magnetic clutch - N25- energised, overload protection
(if fitted) not tripped).*
Note
Depending on the engine, the air conditioner compressor is driven

by different components (belt or drive shaft). To protect these
components and the engine, the pulley or the drive unit of the air
conditioner compressor are fitted with an overload protection de‐
vice, which is triggered if the air conditioner compressor is not
operating smoothly ⇒ Heating, air conditioning; Rep. gr. 87 ; Air
conditioner compressor (vehicle-specific Workshop Manual).
8.1.2 Checking pressures

– Connect air conditioner service station ⇒ page 178 .
Vehicles with electrically operated valves in the refrigerant circuit
which are not open when the system is de-energised (e.g. on the
Audi Q7 e-tron):
Note

after the ignition is switched off. However, for the pressure in the
refrigerant circuit to be checked when the air conditioner is switch‐
ed off, no part of the circuit may be closed off; these valves must
therefore be opened before performing such work ⇒ Heating, air
Finding”).



ing”).
All vehicles
– Read pressures off pressure gauges; there are two possible
results:
♦ The pressure in the refrigerant circuit is lower than indicated
in the table.
♦ The pressure in the refrigerant circuit corresponds to that in‐
dicated in the table or is higher.
Ambient temperature (in de‐ Pressure in refrigerant circuit in
grees centigrade) bar
+15 °C 3.9
+20 °C 4.7
+25 °C 5.6
+30 °C 6.7
+35 °C 7.8
+40 °C 9.1
+45 °C 10.5
Note
♦ The temperature of the refrigerant circuit components should

be equal to the ambient temperature. (the pressure will deviate
from the values in the table if individual components of the
refrigerant circuit are warmer or colder).
♦ On the absolute pressure scale, 0 bar corresponds to an ab‐
solute vacuum. The normal ambient pressure (atmospheric
pressure) corresponds to 1 bar absolute pressure. On the
scales of most pressure gauges, 0 bar corresponds to an ab‐
solute pressure of 1 bar (can be seen from -1 bar mark below
0).
♦ On vehicles with a high-pressure sender - G65- , pressure
sender for refrigerant circuit - G805- or refrigerant pressure
and temperature sender - G395- etc. for which the measured
pressure is displayed in the measured value block, the pres‐
sure measured should coincide with the values in the table ⇒
Workshop Manual).
♦ Pressure can be measured in various units: 1 MPa (mega‐
pascal) is equivalent to 10 bar gauge pressure, or 145 psi; 1
bar absolute pressure is the same as 0 bar gauge pressure,
which is roughly equivalent to atmospheric pressure.
The pressure in the refrigerant circuit is lower than indicated in

the table.
Not enough refrigerant in circuit
– Locate leaks in refrigerant circuit ⇒ page 161 .
– Check high-pressure safety valve.
If the high-pressure safety valve has blown off:
– Check actuation of the radiator fans.
– Check for constricted refrigerant pipe and hose cross-sections
caused by inadequate bending radii.

– Check refrigerant lines and hoses for external damage.

– If no fault is found, clean refrigerant circuit (by flushing with
refrigerant R134a ⇒ page 88 or blowing out with compressed
air and nitrogen ⇒ page 84 ).
The pressure in the refrigerant circuit corresponds to that indica‐
ted in the table or is higher.
– Start engine or activate drive system (e.g. on vehicles with
high-voltage system).
– Set air conditioning system to maximum cooling output.
Note
♦ On vehicles with an air conditioner compressor regulating

valve - N280- , the control current can be read out in the meas‐
ured value block ⇒ Vehicle diagnostic tester (“Self-diagnosis”
Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐
pressor (vehicle-specific Workshop Manual).
♦ On vehicles with an electrical air conditioner compressor -
V470- you can read out the air conditioner compressor speed
via different control units (e.g. via the corresponding air con‐
ditioner control unit or the thermal management control unit -
J1024- ) ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
mode.
Vehicles with a mechanically driven air conditioner compressor

If air conditioner compressor is not driven with engine running or
regulating valve is not actuated:
– Establish and eliminate the cause e.g. by interrogating the air
conditioner event memory.
– Observe test requirements.
– Check the power supply for the air conditioning system mag‐
netic clutch - N25- . If this is OK, service the magnetic clutch.
– Check activation of air conditioner compressor regulating
valve - N280- ⇒ Vehicle diagnostic tester (“Self-diagnosis” or
“Guided Fault Finding” function for air conditioner) and ⇒
Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐
pressor (vehicle-specific Workshop Manual).
Note
♦ If low-pressure switch has been removed to connect air con‐

ditioner service station, jumper electrical connections in rele‐
vant connector for pressure measurement.
♦ Air conditioner compressor is driven by engine via air condi‐
tioning system magnetic clutch - N25- .
♦ The air conditioner compressor regulating valve - N280- is ac‐
tivated by the operating and display unit for front air condition‐
ing system - E87- or the Climatronic control unit - J255- ⇒
Workshop Manual).

Vehicles with electrical air conditioner compressor - V470- (vehi‐

cles with high-voltage system)
If the drive system is active but the electrical air conditioner com‐
pressor is not activated:
– Check activation of air conditioner compressor via corre‐
sponding control unit ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit (vehicle-specific Workshop Manual) and
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode.
All vehicles
♦ Checking pressures on vehicles with a restrictor and reservoir
(with internally regulated air conditioner compressor)
⇒ page 189
♦ Checking pressures on vehicles with an expansion valve and
receiver (with internally regulated air conditioner compressor)
⇒ page 194
♦ Checking pressures on vehicles with restrictor, reservoir and
air conditioner compressor regulating valve - N280- (with ex‐
ternally regulated air conditioner compressor) ⇒ page 200
♦ Checking pressures on vehicles with expansion valve, receiv‐
er and air conditioner compressor regulating valve - N280-
(with externally regulated air conditioner compressor)
⇒ page 207
♦ Check pressures on vehicles with electrically driven air con‐
ditioner compressor (Audi A3 e-tron, Audi Q5 hybrid, Audi Q7
e-tron etc.) ⇒ page 218 .
8.2 Checking pressures - vehicles with re‐

strictor and reservoir (with internally
regulated air conditioner compressor)
Note
♦ Connect air conditioner service station ⇒ page 178 .

– Check the pressures in the refrigerant circuit (with the air con‐
ditioner service station) with the ignition switched off
⇒ page 183 .
The pressures with the ignition switched off correspond to the
specifications.
– Start engine.
– Set engine speed to 2000 rpm.
– Observe the pressure reading (e.g. pressure gauge) of the air

Note
♦ Switching pressures for refrigerant circuit switches are vehi‐

cle-specific.
♦ The port with a valve for the low-pressure switch or on the
evaporator should only be used where the vehicle does not
have a service port on the low-pressure side and access to the
port on the air conditioning system compressor or reservoir is
not possible (measurement accuracy). Only applies for certain
vehicles ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
⇒ “8.2.1 Specifications for pressures in refrigerant circuit”,

page 190
8.2.1 Specifications for pressures in refriger‐

ant circuit
High-pressure side:
Increasing from initial pressure (when connecting pressure
gauges) up to max. 20 bar
Low-pressure side:
Decreasing from initial pressure (on connecting pressure gauges)
to value in graph
A - High pressure (measured at service connection) in bar
B - Low pressure (measured at connection with valve at air con‐
ditioner compressor or at reservoir) in bar
C - Permissible tolerance range
D - Low pressure (measured at connection with valve for low-
pressure switch or at service connection) in bar
E - Permissible tolerance range
Possible deviation from specification Possible causes of fault Fault elimination

• High pressure remains constant Not enough refrigerant in circuit – Localise leak with leak detector
or only increases slightly (above and eliminate.
pressure with engine stopped)
– Re-charge refrigerant circuit.
• Low pressure quickly drops to
value in graph or below
• Required cooling output is not at‐
tained.
• High pressure normal

• Low pressure in line with value in
graph
tained.


• Low pressure too low (see graph)
tained.
Note
If no fault is found for this problem, clean refrigerant circuit (by

flushing with refrigerant R134a ⇒ page 88 or blowing out with
compressed air and nitrogen ⇒ page 84 ).

• High pressure does not rise or ♦ No actuation of the air condi‐ – Check actuation and drive of the
only rises slightly above the pres‐ tioner compressor (magnetic air conditioner compressor and
sure with the engine stopped. clutch). perform repair ⇒ Heating, air
conditioning; Rep. gr. 87 ; Air
• Low pressure does not drop or ♦ The air conditioner compressor conditioner compressor (vehi‐
only drops slightly. is not driven. cle-specific Workshop Manual).
tained.
♦ Constriction or blockage in re‐ – Clean refrigerant circuit (flush

frigerant circuit (e.g. in refriger‐ with refrigerant R134a
ant line between service con‐ ⇒ page 88 or blow out with com‐
nection on low-pressure side pressed air and nitrogen
and air conditioner compres‐ ⇒ page 84 ).
sor).
– Renew hose or pipe if kinked or
constricted.
♦ Air conditioner compressor de‐ – Renew air conditioner compres‐
fective sor.


• High pressure increases above Constriction or blockage in refrig‐ – Run hand over refrigerant circuit
specification erant circuit to check for differences in tem‐
perature ⇒ Heating, air condi‐
• Low pressure quickly drops to tioning; Rep. gr. 87 ; Refrigerant
value in graph or below circuit (vehicle-specific Work‐
• Required cooling output is not at‐ shop Manual).
tained.
• If there is a difference in temper‐
ature at one component:
constricted.
– In the event of clogging, clean

refrigerant circuit (flush with re‐
frigerant R134a ⇒ page 88 or
blow out with compressed air
and nitrogen ⇒ page 84 ).
• If no fault is found:
– Clean refrigerant circuit (flush
⇒ page 88 or blow out with com‐
pressed air and nitrogen
⇒ page 84 ).
• High and low pressure normal at Moisture in refrigerant circuit – Check and if necessary renew
first reservoir (with dryer) and re‐
strictor, then evacuate refriger‐
• High pressure rises above speci‐ ant circuit for at least 3 hours
fied value (see note).
• Low pressure drops to value in
graph or below – Clean refrigerant circuit (flush
• Required cooling output is no lon‐ ⇒ page 88 or blow out with com‐
ger attained. pressed air and nitrogen
⇒ page 84 ).
• High and low pressure normal at
first
• After lengthy operating period,
low pressure drops excessively
(evaporator ices up)
Note
♦ If an issue involving moisture in the refrigerant circuit only oc‐

curs after a lengthy operating period or only infrequently (low
pressure drops below specified value and evaporator ices up),
it is sufficient to renew the dryer (adjust quantity of refrigerant
oil). Subsequently, evacuate refrigerant circuit for at least 3
hours.
♦ It is not initially necessary to clean the refrigerant circuit (flush
with refrigerant R134a ⇒ page 88 or blow out with compressed
air and nitrogen ⇒ page 84 ) when this problem occurs. Nor‐
mally, there is only a small quantity of moisture in the system
which can be removed by lengthy evacuation.


• High pressure normal Air conditioner compressor defective – Clean refrigerant cir‐
cuit (flush with refrig‐
• Low pressure too low (see graph) erant R134a
• Required cooling output is at‐ ⇒ page 88 or blow
tained. out with compressed
air and nitrogen
⇒ page 84 ).
– Renew air condition‐

er compressor.
Note
♦ Observe the following regarding fault “High pressure normal,

low pressure too low”: This fault may cause the evaporator to
ice up or the low-pressure switch - F73- to shut off the air con‐
ditioner compressor although the amount of refrigerant in the
circuit is OK.
♦ On the Audi 100, Audi A6 (up to and including model year
1997) and Audi V8, this fault may result in the air conditioner
compressor being shut off by the operating and display unit (if
the temperature at the fresh air blower drops below -3 °C) ⇒
hicle-specific Workshop Manual) or ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Overview of fitting locations - air conditioner

• High pressure normal or too high Too much refrigerant in circuit – Extract refrigerant
from refrigerant cir‐
• Low pressure too high (see cuit.
graph)
• Noise from air conditioner com‐ • If quantity of refriger‐
pressor (particularly after being ant extracted roughly
switched on) corresponds to
specified capacity:
tained. – Renew air condition‐
er compressor.
• The quantity of re‐
frigerant extracted is
significantly greater
than the prescribed
charge quantity.
– Re-charge refriger‐
ant circuit.
– Repeat test.


• High and low pressure normal Too much refrigerant oil in circuit – Discharge refriger‐
ant circuit.
tained. – Clean refrigerant
circuit (flush with re‐
frigerant R134a
⇒ page 88 or blow
out with com‐
pressed air and ni‐
trogen ⇒ page 84 ).
• High and low pressure normal
• Noise from air conditioner com‐
pressor (particularly after being
switched on)
• Required cooling output is at‐
tained.
Note
♦ Overfilling with refrigerant oil may occur if, for example, the air
conditioner compressor has been renewed without adjusting
the quantity of refrigerant oil.
♦ If there is too much refrigerant oil in the circuit, discharge the
air conditioner compressor and renew the receiver. After
cleaning the refrigerant circuit (flush with refrigerant R134a
⇒ page 88 or blow out with compressed air and nitrogen
⇒ page 84 ), add the correct amount of refrigerant oil to the
circuit ⇒ page 317 .
8.3 Checking pressures - vehicles with ex‐

pansion valve and receiver (with inter‐
nally regulated air conditioner compres‐
sor)
Note

⇒ page 183 .
specifications.
– Start engine.

Note
♦ Switching pressures and design of refrigerant circuit switches

are vehicle-specific.
♦ Measure the pressures at the service connections; the fitting
locations of these connections are vehicle-specific ⇒ Heating,

page 195

ant circuit
High-pressure side:
Low-pressure side:
to value in graph
A - High pressure in bar
B - Low pressure in bar
Possible deviation from Possible causes of fault Fault elimination

specification
• High pressure remains Not enough refrigerant in circuit or – Extract refrigerant from refrigerant cir‐
constant or only increa‐ expansion valve defective cuit.
ses slightly (above pres‐
sure with engine stop‐ • If quantity of refrigerant extracted rough‐
ped) ly corresponds to specified capacity:
• Low pressure quickly – Renew expansion valve.
drops to value in graph
or below – Re-charge refrigerant circuit.
• Required cooling output – Repeat test.
is not attained.
• High pressure normal • The quantity of refrigerant extracted is

substantially less than the specified ca‐
• Low pressure in line with pacity.
value in graph
– Locate leak with leak detector and repair
• Required cooling output it.
is not attained.
– Repeat test.

Note
If no fault can be found and air conditioner operation is not OK

when the test is repeated, clean the refrigerant circuit (flush with
refrigerant R134a ⇒ page 88 or blow out with compressed air and
nitrogen ⇒ page 84 ).
Possible devia‐ Possible causes of Fault elimination

tion from speci‐ fault
fication
• High pres‐ ♦ No actuation of – Check actuation and
sure does the air condition‐ drive of the air condi‐
not rise or er compressor tioner compressor
only rises (magnetic and perform repair ⇒
slightly clutch) Heating, air condi‐
above the tioning; Rep. gr. 87 ;
pressure ♦ The air condi‐ Air conditioner com‐
with the en‐ tioner compres‐ pressor (vehicle-spe‐
gine stop‐ sor is not driven. cific Workshop Man‐
ped. ual).
• Low pres‐
sure does
not drop or
only drops
slightly.
• Required
cooling out‐
put is not at‐
tained.
♦ Constriction or – Clean refrigerant cir‐

blockage in re‐ cuit (flush with refrig‐
frigerant circuit erant R134a
(e.g. in refriger‐ ⇒ page 88 or blow out
ant line between with compressed air
service connec‐ and nitrogen
tion on low-pres‐ ⇒ page 84 ).
sure side and air
conditioner com‐ – Renew hose or pipe if
pressor). kinked or constricted.
♦ Air conditioner – Renew air condition‐

compressor de‐ er compressor.
fective


specification
• High pressure increases ♦ Constriction or blockage in refriger‐ – Run hand over refrigerant circuit to
above specification ant circuit check for differences in tempera‐
ture ⇒ Heating, air conditioning;
• Low pressure quickly ♦ Expansion valve defective Rep. gr. 87 ; Refrigerant circuit;
drops to value in graph System overview - refrigerant cir‐
or below cuit (vehicle-specific Workshop
• Required cooling output Manual).
is not attained.
• If there is a difference in tempera‐
ture at one component:
constricted.
– In the event of clogging, clean re‐

frigerant circuit (flush with refriger‐
ant R134a ⇒ page 88 or blow out
with compressed air and nitrogen
⇒ page 84 and renew expansion
valve if applicable).
– Clean refrigerant circuit (flush with
refrigerant R134a ⇒ page 88 or
blow out with compressed air and
nitrogen ⇒ page 84 and renew ex‐
pansion valve if applicable).
– Repeat test.
Note
If operation is not OK after cleaning the refrigerant circuit (flushing

with refrigerant R134a ⇒ page 88 or blowing out with compressed
air and nitrogen ⇒ page 84 ), renew the expansion valve.

specification
• High and low pressure ♦ Expansion valve defective – Renew receiver (with dryer) and
normal at first evacuate refrigerant circuit for at
♦ Moisture in refrigerant circuit least 3 hours (see notes).
• After some time, high
pressure increases – Check expansion valve for dirt or
above specification and corrosion and renew if necessary
low pressure drops to
value in graph or below – Clean refrigerant circuit (flush with
• Required cooling output refrigerant R134a ⇒ page 88 or
is no longer attained. blow out with compressed air and
• High and low pressure
normal at first
• After lengthy operating
period, low pressure
drops excessively
(evaporator ices up)

Note

hours.
Possible deviation from specifica‐ Possible causes of fault Fault elimination

tion
• High pressure normal or too ♦ Too much refrigerant in circuit – Extract refrigerant from refrigerant
high circuit.
♦ Expansion valve or air condi‐
• Low pressure too high (see tioner compressor defective. • If amount of refrigerant extracted
graph) roughly corresponds to specified
• Required cooling output is not capacity:
attained – Renew expansion valve.
• Air conditioner compressor
noise (particularly after switch- – Re-charge refrigerant circuit.
on).
– Repeat test.
• The quantity of refrigerant extrac‐

ted is significantly greater than the
prescribed charge quantity.
– Repeat test.
Note
If operation of the air conditioning system is not OK when the test

is repeated, re-fit the old expansion valve and clean the refriger‐
ant circuit (flush with refrigerant R134a ⇒ page 88 or blow out with
compressed air and nitrogen ⇒ page 84 ). Then renew the air
conditioner compressor and receiver.

tion
• High pressure only increases Air conditioner compressor de‐ – Clean refrigerant circuit (flush with
slightly above pressure with fective refrigerant R134a ⇒ page 88 or
engine stopped blow out with compressed air and
• Low pressure only drops slight‐
ly – Renew the air conditioner com‐
• Required cooling output is not pressor and receiver.
attained.


tion
• High pressure normal Expansion valve or air condition‐ – Renew expansion valve.
er compressor defective.
• Low pressure too low (see – Re-charge refrigerant circuit.
graph)
• Required cooling output is at‐ – Repeat test.
tained.
Note
♦ If operation of the air conditioning system is not OK when the

test is repeated, re-fit the old expansion valve and clean the
refrigerant circuit (flush with refrigerant R134a ⇒ page 88 or
blow out with compressed air and nitrogen ⇒ page 84 ). Then
renew the air conditioner compressor and receiver.
♦ In this case, the evaporator may ice up although the amount
of refrigerant in the refrigerant circuit is OK.

tion
• High and low pressure normal Too much refrigerant oil in circuit – Discharge refrigerant circuit.
• Required cooling output is not – Clean refrigerant circuit (flush with
attained. refrigerant R134a ⇒ page 88 or
• High and low pressure normal
• Noise from air conditioner com‐
pressor (particularly after being
switched on)
• Required cooling output is at‐
tained.
Note

8.4 Checking pressures - vehicles with re‐

strictor, reservoir and air conditioner
compressor regulating valve - N280-
(with externally regulated air conditioner
compressor)
Note

⇒ page 183 .
specifications.
– Start engine.
Note
♦ The switching pressures for actuation of -N280- and the radi‐

ator fans - V7- are vehicle-specific.

page 200

ant circuit
High-pressure side:
Increasing from initial pressure (on connection of pressure
gauges) up to 20 bar

Low-pressure side:
to value in graph
A - Low pressure (measured at service connection) in bar abso‐
lute pressure.
B - Control current for air conditioner compressor regulating valve
- N280- in amps

Note
♦ In the event of a very high cooling output requirement (e.g.

high ambient temperature and high fresh air blower speed at
low engine speed), the air conditioner compressor cannot in‐
itially set the pressure on the low-pressure end to the value
-C- given in the graph (e.g. for a certain time after switching
on the air conditioner). The air conditioner compressor is ac‐
tuated with the maximum specified control current, however
the delivery volume of the air conditioner compressor is no
longer sufficient under these ambient conditions and at this
engine speed to reduce the pressure on the low-pressure end
to the value in the graph. One way of checking the control ac‐
tion of the air conditioner compressor under these conditions
is to activate the fresh air blower with only approx. 40% of the
maximum voltage and to check the pressures at reduced fresh
air blower speed ⇒ Vehicle diagnostic tester (“self-diagnosis”
Heating, air conditioning; Rep. gr. 00 ; Repair instructions;
Checking cooling output or ⇒ Heating, air conditioning; Rep.
ual).
♦ Under unfavourable conditions (very high ambient tempera‐
tures, high humidity), pressure on high-pressure end may
increase to max. 29 bar.
♦ Control current -B- is displayed in measured value block of
operating and display unit for front air conditioning system -
E87- or operating and display unit ( Climatronic control unit -
J255- ).
♦ The pressure in the refrigerant circuit measured by the high-
pressure sender - G65- or the refrigerant pressure and tem‐
perature sender - G395- is displayed in the measured value
block of -E87- or of the operating and display unit ( Climatronic
control unit - J255- ) ⇒ Vehicle diagnostic tester (“Self-diag‐
nosis” or “Guided Fault Finding” function for air conditioner)
♦ The low pressure settles as a function of the control current
for the air conditioner compressor regulating valve - N280-
within the air conditioner compressor output range in the tol‐
erance band.
tures, high humidity), the air conditioner compressor output
may not always be sufficient to attain the specified value.
♦ If the compressor capacity utilisation is greater than 90 %, the
pressure on the low-pressure end may be in excess of the
tolerance range “C” shown in the graph (the compressor out‐
put no longer suffices).
♦ The specified operating current for the regulating valve must
be greater than 0.3 A to ensure reliable actuation of the regu‐
lating valve.
♦ “0 bar absolute pressure” corresponds to an absolute vacuum.
Normal ambient pressure corresponds to an absolute pres‐
sure of 1 bar. On the scales of most pressure gauges, 0 bar
corresponds to an absolute pressure of one bar (can be seen
from “-1 bar” mark below “0”).

♦ In the "maximum cooling output" setting, the control current is

regulated to approx. 0.65 (up to 0.85 A for specific vehicles);
this is displayed in the measured value block ⇒ Vehicle diag‐
nostic tester (“Self-diagnosis” or “Guided Fault Finding” func‐
tion for air conditioner) and ⇒ Heating, air conditioning; Rep.
gr. 00 ; Repair instructions; Checking cooling output or ⇒
Heating, air conditioning; Rep. gr. 87 ; Overview of fitting lo‐
cations - air conditioner (vehicle-specific Workshop Manual).

specification
• High pressure remains ♦ Actuation of air conditioner com‐ – Check activation of -N280- ⇒ Heat‐
constant or only increa‐ pressor regulating valve - N280- ing, air conditioning; Rep. gr. 87 ;
ses slightly (above pres‐ not OK Refrigerant circuit (vehicle-specific
sure with engine stop‐ Workshop Manual).
ped) ♦ Not enough refrigerant in circuit
– Locate leak with leak detector and
• Low pressure quickly repair it.
drops to value in graph or
below – Re-charge refrigerant circuit.
• Required cooling output
is not attained.

• Low pressure too low
(see graph)
• Required cooling output
is not attained.
Note
If no fault is found for this problem, clean refrigerant circuit (by

Possible deviation from spec‐ Possible causes of fault Fault elimination

ification
• High pressure does not ♦ No actuation of the air conditioner – Check actuation and drive of the air
rise or only rises slightly compressor ( air conditioner conditioner compressor and perform
above the pressure with compressor regulating valve - repair ⇒ Heating, air conditioning;
the engine stopped. N280- ) Rep. gr. 87 ; Air conditioner com‐
pressor (vehicle-specific Workshop
• Low pressure does not ♦ The air conditioner compressor is Manual).
drop or only drops slightly. not driven.
• Required cooling output is – Check actuation and operation of -
not attained. N280- .
♦ Constriction or blockage in refrig‐ – Clean refrigerant circuit (flush with

erant circuit (e.g. in refrigerant refrigerant R134a ⇒ page 88 or blow
line between service connection out with compressed air and nitrogen
on low-pressure side and air con‐ ⇒ page 84 ).
ditioner compressor).
– Renew hose or pipe if kinked or con‐
stricted.
♦ Air conditioner compressor regu‐ – Check operation of -N280- , remove
lating valve - N280- defective -N280- if applicable and check for
contamination ⇒ page 269 .


ification
♦ Air conditioner compressor de‐ – Renew air conditioner compressor.
fective

ification
• High pressure increases ♦ Actuation of air conditioner com‐ – Check activation of -N280- ⇒ Heat‐
above specification pressor regulating valve - N280- ing, air conditioning; Rep. gr. 87 ;
not OK Refrigerant circuit (vehicle-specific
• Low pressure quickly Workshop Manual).
drops to value in graph or ♦ Constriction or blockage in refrig‐
below erant circuit – Run hand over refrigerant circuit to
• Required cooling output is check for differences in temperature.
not attained.
• If there is a difference in temperature
at one component:
stricted.
– Flush the refrigerant circuit with com‐

pressed air and nitrogen in the event
of an obstruction.
refrigerant R134a ⇒ page 88 or blow
out with compressed air and nitrogen
⇒ page 84 ).

ification
• High and low pressure ♦ Actuation of air conditioner com‐ – Check activation of -N280- ⇒ Heat‐
normal at first, after some pressor regulating valve - N280- ing, air conditioning; Rep. gr. 87 ;
time high pressure increa‐ not OK Refrigerant circuit (vehicle-specific
ses above specification Workshop Manual).
and
– Renew reservoir (with dryer) and
• Low pressure drops to val‐ evacuate refrigerant circuit for at
ue in graph or below least 3 hours (see note).
• Required cooling output is
no longer attained.
• High and low pressure ♦ Air conditioner compressor regu‐ – Check operation of -N280- , remove
normal at first lating valve - N280- defective -N280- if applicable and check for
• After lengthy operating pe‐
riod, low pressure drops ♦ Moisture in refrigerant circuit – Clean refrigerant circuit (flush with
excessively (evaporator refrigerant R134a ⇒ page 88 or blow
ices up) out with compressed air and nitrogen
⇒ page 84 ).

Note

hours.
♦ A problem with evaporator output temperature sender - G263-
can also cause icing-up of refrigerant circuit. If this problem
occurs, you should also check the measured value of the
evaporator output temperature sender - G263- ⇒ Vehicle di‐
agnostic tester (“Self-diagnosis” or “Guided Fault Finding”
function for air conditioner) and ⇒ Heating, air conditioning;
Rep. gr. 00 ; Repair instructions; Checking cooling output or

ification
• High pressure normal ♦ Actuation of air conditioner com‐ – Check activation of -N280- ⇒ Heat‐
pressor regulating valve - N280- ing, air conditioning; Rep. gr. 87 ;
• Low pressure too low (see not OK Refrigerant circuit (vehicle-specific
graph) Workshop Manual).
♦ Air conditioner compressor regu‐
• Required cooling output is lating valve - N280- defective
attained. – Check operation of -N280- , remove
-N280- if applicable and check for
♦ Air conditioner compressor de‐ – Clean refrigerant circuit (flush with
fective refrigerant R134a ⇒ page 88 or
– Renew air conditioner compressor.
Note
Observe the following regarding fault “High pressure normal, low

pressure too low”: This fault may cause the evaporator to ice up
although the amount of refrigerant in the circuit is OK. Check
measured values of evaporator output temperature sender -
G263- and actuation of air conditioner compressor regulating
valve - N280- . If the measured value of the evaporator output
temperature sender - G263- is incorrect, the evaporator may ice
up or the cooling output may not be attained ⇒ Vehicle diagnostic
tester (“Self-diagnosis” or “Guided Fault Finding” function for air
conditioner) and ⇒ Heating, air conditioning; Rep. gr. 00 ; Repair
instructions; Checking cooling output or ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific Workshop
Manual).


ification
• High pressure normal or ♦ Actuation of air conditioner compressor – Check activation of -N280- ⇒
too high regulating valve - N280- not OK Heating, air conditioning;
Rep. gr. 87 ; Refrigerant cir‐
• Low pressure too high ♦ Too much refrigerant in circuit cuit (vehicle-specific Work‐
(see graph) shop Manual).
• Noise from air conditioner
compressor (particularly – Extract refrigerant from refrig‐
after being switched on) erant circuit.
• Required cooling output is • If amount of refrigerant ex‐

not attained. tracted roughly corresponds
to specified capacity:
– Renew air conditioner com‐
pressor.
• The quantity of refrigerant ex‐

tracted is significantly greater
than the prescribed charge
quantity.
– Repeat test.
• High and low pressure ♦ Actuation of air conditioner compressor – Check actuation of -N280- .
normal regulating valve - N280- not OK
– Discharge refrigerant circuit.
• Required cooling output is ♦ Too much refrigerant oil in circuit
not attained.
• High and low pressure – Clean refrigerant circuit (flush

normal. with refrigerant R134a
⇒ page 88 or blow out with
• Air conditioner compres‐ compressed air and nitrogen
sor noise (particularly after ⇒ page 84 ).
switch-on).
attained.
Note

8.5 Checking pressures - vehicles with ex‐

pansion valve, receiver and air condi‐
tioner compressor regulating valve -
N280- (with externally regulated air
conditioner compressor)
Note

♦ If problems are only encountered at one evaporator on vehi‐
cles fitted with two evaporators, check whether the pressures
in the refrigerant circuit are OK. Check for cross-sectional re‐
striction or blockage of line connection between faulty evapo‐
rator and outgoing line connection at refrigerant line distribu‐
tion point. If no fault is found, discharge the refrigerant circuit
and re-fill it with the specified quantity of refrigerant. Then
check the pressures and the cooling output of the air condi‐
tioner again. If the problem persists, renew the expansion
valve upstream of the faulty evaporator ⇒ Heating, air condi‐
shop Manual).
⇒ page 183 .
specifications.
– Start engine.
Note
♦ The switching pressures for actuation of the air conditioner

compressor regulating valve - N280- and the radiator fans -
V7- are vehicle-specific.

page 207

ant circuit
High-pressure side:

Low pressure:
to value in graph
A - Low pressure (measured at service connection) in bar abso‐
lute pressure.
B - Control current for air conditioner compressor regulating valve
- N280- in amps
C - Permissible tolerance range (applicable to compressor ca‐
pacity utilisation of 10...90 %).

Note
♦ In the event of a very high cooling output requirement (e.g.

high ambient temperature and high fresh air blower speed at
low engine speed), the air conditioner compressor cannot in‐
itially set the pressure on the low-pressure end to the value
-C- given in the graph (e.g. for a certain time after switching
on the air conditioner). The air conditioner compressor is ac‐
tuated with the maximum specified control current, however
the delivery volume of the air conditioner compressor is no
longer sufficient under these ambient conditions and at this
engine speed to reduce the pressure on the low-pressure end
to the value in the graph. One way of checking the control ac‐
tion of the air conditioner compressor under these conditions
is to activate the fresh air blower with only approx. 40% of the
maximum voltage and to check the pressures at reduced fresh
air blower speed ⇒ Vehicle diagnostic tester (“self-diagnosis”
ual).
tures, high humidity), the pressure on the high-pressure side
may increase to max. 29 bar.
♦ Control current -B- is displayed in measured value block of
operating and display unit for front air conditioning system -
E87- or Climatronic control unit - J255- .
♦ High pressure measured by the high-pressure sender - G65-
(or refrigerant pressure and temperature sender - G395- /
pressure sender for refrigerant circuit - G805- ) is displayed as
a measured value of -E87- or of the air conditioning system
control unit - J301- / operating and display unit ( Climatronic
control unit - J255- ).
♦ The low pressure settles as a function of the control current
for the air conditioner compressor regulating valve - N280- and
the control characteristic of the expansion valve within the air
conditioner compressor output range in the tolerance band.
tures, high humidity), the air conditioner compressor output
may not always be sufficient to attain the specified value.
♦ If the compressor capacity utilisation is greater than 90 %, the
pressure on the low-pressure end may be in excess of the
tolerance range “C” shown in the graph (the compressor out‐
put no longer suffices).
♦ The specified operating current for the air conditioner com‐
pressor regulating valve - N280- must be greater than 0.3 A to
ensure reliable valve actuation.
♦ In the “maximum cooling output” setting, the control current for
the air conditioner compressor regulating valve - N280- is
regulated to approx. 0.65 A (up to 0.85 A). This measured val‐
ue is vehicle-specific and displayed in the measured value
block.


solute vacuum. Normal ambient pressure corresponds to an
absolute pressure of 1 bar. On the scale of most pressure
gauges, 0 bar corresponds to an absolute pressure of 1 bar
(can be seen from -1 bar mark below 0) ⇒ Vehicle diagnostic
tester (“Self-diagnosis” or “Guided Fault Finding” function for
air conditioner) and ⇒ Heating, air conditioning; Rep. gr. 00 ;
Repair instructions; Checking cooling output or ⇒ Heating, air
Workshop Manual).
Possible deviation from speci‐ Possible causes of fault Fault elimination

fication
• High pressure remains con‐ ♦ Actuation of air conditioner compres‐ – Check activation of -N280- ⇒
stant or only increases sor regulating valve - N280- not OK Heating, air conditioning;
slightly (above pressure Rep. gr. 87 ; Refrigerant cir‐
with engine stopped) ♦ Not enough refrigerant in circuit cuit (vehicle-specific Work‐
shop Manual).
• Low pressure quickly drops ♦ Expansion valve defective
to value in graph or below – Extract refrigerant from re‐
• Required cooling output is frigerant circuit.
not attained.
• If quantity of refrigerant ex‐
tracted is substantially less
than specified capacity:
• High pressure normal – Locate leak with leak detec‐

tor and repair it.
• Low pressure in line with
value in graph – Re-charge refrigerant circuit.
not attained. – Repeat test.
• High pressure normal • If amount of refrigerant ex‐

tracted roughly corresponds
• Low pressure too low (see to specified capacity:
graph)
– Renew expansion valve.
not attained. – Re-charge refrigerant circuit.
– Repeat test.

Note
♦ If no fault is found for this problem, clean refrigerant circuit (by

♦ Check the measured values of the evaporator output temper‐
ature sender - G263- and actuation of -N280- . If the measured
value of the evaporator output temperature sender - G263- is
not OK, the evaporator may ice up or the cooling output is not
attained.
♦ If, after renewing the expansion valve, operation of the air
conditioning system is not OK when the test is repeated (re-fit
old expansion valve), clean the refrigerant circuit (flush with
refrigerant R134a ⇒ page 88 or blow out with compressed air
and nitrogen ⇒ page 84 ). Then renew the air conditioner com‐
pressor and receiver.
♦ If the expansion valve is defective (permanently closed or
does not open sufficiently), -N280- is actuated to maximum
output and the low pressure drops to the value in the graph or
below (the air conditioner compressor draws off refrigerant
from the low-pressure end). However, as refrigerant cannot
flow via the expansion valve, the cooling output is not attained
and the high pressure may also not increase or only increase
slightly since there is no energy exchange ⇒ Vehicle diag‐

tion from specifi‐ fault
cation
• High pres‐ ♦ No actuation of – Check actuation
sure does not the air condition‐ and drive of the air
rise or only er compressor conditioner com‐
rises slightly ( air conditioner pressor and per‐
above the compressor regu‐ form repair ⇒ Heat‐
pressure with lating valve - ing, air condition‐
the engine N280- ) ing; Rep. gr. 87 ; Air
stopped. conditioner com‐
♦ The air condition‐ pressor (vehicle-
• Low pressure er compressor is specific Workshop
does not drop not driven. Manual).
or only drops
slightly.
• Required
cooling out‐
put is not at‐
tained.
♦ Air conditioner – Check operation of

compressor regu‐ -N280- , remove -
lating valve - N280- if applicable
N280- defective. and check for con‐
tamination
⇒ page 269 .


cation
♦ Constriction or – Clean refrigerant
blockage in re‐ circuit (flush with re‐
frigerant circuit frigerant R134a
(e.g. in refrigerant ⇒ page 88 or blow
line between out with com‐
service connec‐ pressed air and ni‐
tion on low-pres‐ trogen ⇒ page 84 ).
sure side and air
conditioner com‐ – Renew hose or pipe
pressor). if kinked or constric‐
ted.
♦ Air conditioner – Renew air condi‐
compressor de‐ tioner compressor.
fective
Note
♦ In the event of this problem, make sure the air conditioner

compressor (air conditioner compressor shaft) is actually be‐
ing driven via the pulley/drive unit ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor (vehicle-specific
Workshop Manual).
♦ As of Model Year 2012, air conditioner compressors with both
-N280- and an air conditioning system magnetic clutch - N25-
fitted at the pulley are to be introduced for certain engines and
models. In the event of this problem, make sure -N25- is ac‐
tually being actuated and that the air conditioner compressor
(air conditioner compressor shaft) is being driven via the pulley
parts catalogue .


ification
• High pressure increases ♦ Actuation of air conditioner com‐ – Check activation of -N280- ⇒ Heat‐
above specification pressor regulating valve - N280- ing, air conditioning; Rep. gr. 87 ;
not OK Refrigerant circuit (vehicle-specific
• Low pressure quickly Workshop Manual).
drops to value in graph ♦ Constriction or blockage in refrig‐
erant circuit – Run hand over refrigerant circuit to
not attained. ♦ Expansion valve defective check for differences in temperature.

at one component:
stricted.
– In the event of clogging, clean refrig‐
erant circuit (flush with refrigerant
R134a ⇒ page 88 or blow out with
compressed air and nitrogen
⇒ page 84 ).
– Repeat test.
⇒ page 84 ).
– Repeat test if operation is not OK:
– Renew expansion valve and receiv‐

er.

Note
♦ If the function of the air conditioning system is not OK when

the test is repeated, renew expansion valve and receiver.
does not open sufficiently), the air conditioner compressor
regulating valve - N280- is actuated to maximum output and
the low pressure drops to the value in the graph or below (the
air conditioner compressor draws off refrigerant from the low-
pressure end). However, as refrigerant cannot flow via the
expansion valve, the cooling output is not attained and the high
pressure may also not increase or only increase slightly since
there is no energy exchange ⇒ Vehicle diagnostic tester
(“Self-diagnosis” or “Guided Fault Finding” function for air con‐
ditioner) and ⇒ Heating, air conditioning; Rep. gr. 00 ; Repair
instructions; Checking cooling output or ⇒ Heating, air condi‐
shop Manual).

fication
• High and low pressure nor‐ ♦ Actuation of air conditioner compres‐ – Check activation of -N280- ⇒
mal at first, but after a while: sor regulating valve - N280- not OK Heating, air conditioning;
• High pressure rises above ♦ Moisture in refrigerant circuit cuit (vehicle-specific Work‐
specified value shop Manual).
• Low pressure drops to val‐
ue in graph or below – Clean refrigerant circuit
(flush with refrigerant R134a
• Required cooling output is ⇒ page 88 or blow out with
no longer attained. compressed air and nitrogen
⇒ page 84 ).
• High and low pressure nor‐ – Renew receiver with dryer.
mal at first
– Evacuate refrigerant circuit
• After lengthy driving time, for at least 3 hours.
low pressure drops below
specification (evaporator – Re-charge refrigerant circuit.
ices up)
– Repeat test.
♦ Air conditioner compressor regulating – Check operation of -N280- ,
valve - N280- defective remove -N280- if applicable
and check for contamination
⇒ page 269 .

Note

it is sufficient to renew the dryer in the receiver (adjust quantity
of refrigerant oil). Subsequently, evacuate refrigerant circuit
for at least 3 hours.
♦ A problem with evaporator output temperature sender - G263-
can also cause icing-up of refrigerant circuit. If this problem
occurs, you should also check the measured value of the
evaporator output temperature sender - G263- ⇒ Vehicle di‐
agnostic tester (“Self-diagnosis” or “Guided Fault Finding”
function for air conditioner) and ⇒ Heating, air conditioning;
Rep. gr. 00 ; Repair instructions; Checking cooling output or

fication
• High pressure normal ♦ Actuation of air conditioner compres‐ – Check activation of -N280- ⇒
sor regulating valve - N280- not OK Heating, air conditioning;
• Low pressure too low (see Rep. gr. 87 ; Refrigerant cir‐
graph) cuit (vehicle-specific Work‐
• Required cooling output is shop Manual).
attained.
– Clean refrigerant circuit
⇒ page 84 ) (not always nec‐
essary, refer to notes).
♦ Air conditioner compressor regulating – Check operation of -N280- ,
valve - N280- defective remove -N280- if applicable
and check for contamination
⇒ page 269 .
♦ Expansion valve or air conditioner – Renew expansion valve and
compressor defective. receiver.
♦ Air conditioner compressor defective – Re-charge refrigerant circuit.
– Repeat test if operation is not

OK:

pressor.
– Repeat test.

Note
♦ Observe the following regarding fault “High pressure normal,

low pressure too low”: This fault may cause the evaporator to
ice up although the amount of refrigerant in the circuit is OK.
♦ If the problem is with -N280- (the regulating valve is not actu‐
ated but the air conditioner compressor operates neverthe‐
less), the refrigerant circuit does not have to be cleaned (by
compressed air and nitrogen ⇒ page 84 ). In this case it is
sufficient to renew the air conditioner compressor (observe
quantity of refrigerant oil in compressor).
from the low-pressure end). As refrigerant cannot however
flow via expansion valve, cooling output is not attained and
high pressure may either not increase or only slightly due to
the absence of energy conversion.
♦ Check the measured values of the evaporator output temper‐
ature sender - G263- and actuation of -N280- . If the measured
value of the evaporator output temperature sender - G263- is
incorrect, the evaporator may ice up or the cooling output may
not be attained ⇒ Vehicle diagnostic tester (“Self-diagnosis”
ual).


fication
• High pressure normal or too ♦ Actuation of air conditioner compres‐ – Check activation of -N280- ⇒
high sor regulating valve - N280- not OK Heating, air conditioning;
• Low pressure too high (see ♦ Too much refrigerant in circuit cuit (vehicle-specific Work‐
graph) shop Manual).
♦ Expansion valve defective
compressor (particularly af‐ ♦ Air conditioner compressor defective – Extract refrigerant from re‐
ter being switched on) frigerant circuit.
• Required cooling output is • The quantity of refrigerant

attained. extracted corresponds
roughly to the actual capaci‐
ty.
– Renew expansion valve and
receiver.

OK:

pressor.

tracted is significantly great‐
er than specified capacity:
– Repeat test.
Note
♦ This fault may also be caused by too much refrigerant oil in

the circuit. Overfilling with refrigerant oil may occur if, for ex‐
ample, the air conditioner compressor has been renewed
without adjusting the quantity of refrigerant oil.
from the low-pressure end). However, as refrigerant cannot
flow via the expansion valve, the cooling output is not attained
and the high pressure may also not increase or only increase


fication
• High and low pressure nor‐ ♦ Actuation of air conditioner compres‐ – Check activation of -N280- ⇒
mal sor regulating valve - N280- not OK Heating, air conditioning;
• Required cooling output is ♦ Too much refrigerant in circuit cuit (vehicle-specific Work‐
attained. shop Manual).

⇒ page 84 ).
• High and low pressure nor‐ – Add correct quantity of refrig‐
mal erant oil to circuit (refer to
note).
compressor (particularly af‐ – Re-charge refrigerant circuit.
ter being switched on)
• Required cooling output is – Repeat test if operation is not
attained. OK:
– Repeat test.
Note
♦ If the expansion valve is defective (permanently open), the
evaporator temperature is no longer regulated such that only
refrigerant in gas form exits from the evaporator. Under certain
usage conditions, liquid droplets may then be drawn in by the
air conditioner compressor and result in noise (liquid cannot
be compressed).
8.6 Checking pressures - vehicles with elec‐

trically driven air conditioner compres‐
sor (vehicles with high-voltage system)

⇒ “7 Connecting air conditioner service station ”, page 178

⇒ “8 Checking pressures”, page 183
Note
If problems are only encountered at one evaporator on vehicles

fitted with two evaporators (one in air conditioning unit and one in
battery cooling module or heat exchanger for high-voltage bat‐
tery), check whether the pressures in the refrigerant circuit are
OK. Check the pipe connection between the problematic evapo‐
rator and the outgoing pipe connection at the refrigerant pipe
distribution point (for cross-sectional restriction or blockage, e.g.
in restrictor in the refrigerant line to the heat exchanger for high-
voltage battery). If no fault is found, discharge the refrigerant
circuit and re-fill it with the specified quantity of refrigerant. Then
check the pressures and the cooling output of the air conditioner
again. If the problem persists, check/renew the following compo‐
nents: if the problem only occurs on the evaporator in the air
conditioning unit, check/renew the shut-off valve upstream of the
evaporator (e.g. -N516- or -N541- ). When not activated, this
component is open and allows the refrigerant to flow through.
Renew the expansion valve at the evaporator in the air condition‐
ing unit if no fault is found on -N516- / -N541- . If the problem only
occurs on the evaporator for cooling the high-voltage components
(e.g. in the battery cooling module), check the actuation of shut-
off valve -N517- on the expansion valve on the evaporator in the
battery cooling module (when not activated, it is closed and does
not allow the refrigerant to flow through). If the problem only oc‐
curs on the heat exchanger for high-voltage battery, check the
shut-off valve -N542- (the valve is open when it is not activated
and allows refrigerant to flow through) and the restrictor integrated
in the refrigerant line ⇒ Heating, air conditioning; Rep. gr. 87 ;
⇒ page 183 .
specifications.
– To minimise the number of automatic engine starts when the
vehicle's drive system is active during test and measurement
work, charge the vehicle batteries e.g. with the battery
charger 60A - VAS 5904- in battery standby mode ⇒ Electrical
system; General information; Rep. gr. 27 ; Battery; Charging
battery and ⇒ Electrical system; Rep. gr. 93 ; General warning
instructions for work on the high-voltage system .
Note
♦ Move the selector lever to position “P” and activate the parking
brake before performing test and measurement work for which
the ignition must be switched on but where the vehicle's drive
system does not need to be active.
♦ On vehicles with a high-voltage system, the engine does not
have to be running to check the pressures in the refrigerant
circuit.
♦ The status of the drive system (READY) is shown by the con‐
trol unit in dash panel insert - J285- via the “power meter” ⇒
Owner's Manual .
♦ Activating vehicle drive system (check "READY" display in
control unit in dash panel insert - J285- ) ⇒ Owner's Manual

– Activate vehicle drive system ⇒ Owner's Manual .

– Switch on air conditioner.
Note
♦ The electrically driven air conditioner compressor is actuated

by the vehicle electronics. The engine speed has no influence
on the cooling output of the air conditioner.
♦ When the vehicle is stationary or only moving slowly (up to a
speed of approx. 45 km/h), the air conditioner compressor is
not activated at the maximum specified speed (of approx.
8500 rpm); the air conditioner compressor speed is limited to
approx. 5000 rpm.
♦ Activation of the electrically driven air conditioner compressor
can be monitored via Guided Fault Finding ⇒ Vehicle diag‐
nostic tester, “Guided Fault Finding” mode for air conditioner
and battery regulation .
⇒ “8.6.1 Specifications for pressures in refrigerant circuit on ve‐

hicles without heat pump”, page 220
⇒ “8.6.2 Specifications for pressures in refrigerant circuit on ve‐
hicles with heat pump”, page 240

ant circuit on vehicles without heat pump
Note
No non-return valves are installed in the refrigerant circuit on ve‐

hicles with high-voltage system on which no heat pump is fitted
(e.g. Audi A3 e-tron, Audi Q5 hybrid, Audi A6 hybrid and Audi A8
hybrid). On these vehicles, however, valves are installed in the
refrigerant circuit with regulate the flow of refrigerant to the evap‐
orator (in the heater and air conditioning unit) or to the heat
exchanger for cooling high-voltage system components. These
valves only have 2 operating positions (open or closed) ⇒ Heat‐
“Guided Fault Finding” mode for air conditioner and battery reg‐
ulation .
High-pressure side:
Low-pressure side:
Dropping from initial pressure (when connecting pressure
gauges) to a value between 1.5 and 2.3 bar absolute (depending
on cooling output required)
Air conditioner compressor speed:
Between 800 and 8600 rpm depending on cooling output required
(currently max. 5000 rpm with vehicle stationary)

Note
♦ The temperature of the air downstream of the evaporator, the

current air conditioner compressor speed and the refrigerant
pressure on the high-pressure side are displayed as meas‐
ured values by various control units depending on the vehicle
(e.g. operating and display unit, Climatronic control unit -
J255- , operating and display unit for front air conditioning
system - E87- , thermal management control unit - J1024- etc.)
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode for
air conditioner and ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
♦ If a very high cooling output is required (e.g. high ambient
temperature and high fresh air blower speed), the air condi‐
tioner compressor cannot initially set the pressure on the low-
pressure side to the necessary value (e.g. for a certain time
after switching on the air conditioner). When the vehicle is sta‐
tionary or only moving slowly (up to a speed of approx. 45 km/
h), the air conditioner compressor is not activated at the max‐
imum specified speed (of approx. 8500 rpm); the air condi‐
tioner compressor speed is limited to approx. 5000 rpm.
Limitation of the maximum permissible air conditioner com‐
pressor speed is only cancelled at vehicle speeds above
approx. 45 km/h. At an air conditioner compressor speed of
5000 rpm, with a high ambient temperature and a high fresh
air blower speed (unfavourable ambient conditions), the out‐
put (delivery volume) of the air conditioner compressor is not
initially sufficient to reduce the pressure on the low-pressure
side to the specified value. One way of checking the control
action of the air conditioner compressor under these condi‐
tions is to actuate the fresh air blower with only approx. 40 %
of the maximum voltage and to check the pressures at reduced
fresh air blower speed ⇒ Vehicle diagnostic tester using the
“Guided Fault Finding” function of the air conditioner and the
battery regulation and ⇒ Heating, air conditioning; Rep. gr.
00 ; Repair instructions; Checking the cooling output (vehicle-
♦ The specified speed of the air conditioner compressor is dis‐
played as a measured value by various control units depend‐
ing on the vehicle (e.g. operating and display unit, Climatronic
control unit - J255- ) ⇒ Vehicle diagnostic tester in “Guided
Fault Finding” mode for air conditioning system and ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations).
♦ The high pressure measured by the corresponding sender
(e.g. refrigerant pressure and temperature sender - G395- or
pressure sender for refrigerant circuit - G805- ) is displayed as
a measured value by the corresponding control unit (e.g. op‐
erating and display unit, Climatronic control unit - J255- ) ⇒
Vehicle diagnostic tester in “Guided Fault Finding” mode for
air conditioner and ⇒ Heating, air conditioning; Rep. gr. 00 ;
Repair instructions; Checking cooling output (vehicle-specific
Workshop Manual).
♦ Depending on the speed of the air conditioner compressor and
the control characteristic of the expansion valve, the low pres‐
sure settles in the tolerance band within the air conditioner
compressor output range (1.5 to 2.3 bar).
♦ The specified air conditioner compressor speed must be high‐
er than 1500 rpm for this test.

♦ In the “maximum cooling output” setting, the specified speed

is regulated to approx. 4000 to 5000 rpm. This value is vehicle-
specific and is displayed as a measured value by the corre‐
sponding control unit (e.g. operating and display unit,
Climatronic control unit - J255- ) ⇒ Vehicle diagnostic tester
in “Guided Fault Finding” mode for air conditioner and battery
regulation .
absolute pressure of 1 bar. On the scale of most pressure
gauges, 0 bar corresponds to an absolute pressure of 1 bar
(can be seen from -1 bar mark below 0) ⇒ Vehicle diagnostic
tester using the “Guided Fault Finding” function for the air con‐
ditioner and ⇒ Heating, air conditioning; Rep. gr. 00 ; Repair
instructions; Checking the cooling output (vehicle-specific
Workshop Manual).
♦ On vehicles with two evaporators (e.g. Audi A8 hybrid: one in
the air conditioning unit and one for cooling the high-voltage
components e.g. in the battery cooling module / Audi A3 e-
tron: in the heat exchanger for high-voltage battery), if the
measured temperature corresponds to or is below the speci‐
fied value at one evaporator but the required specified value
is not attained at the other evaporator, the system is controlled
as follows: the responsible control unit ( -J840- or -J255- ) ac‐
tivates the electric air conditioner compressor - JX1- at a
higher speed via various other control units (e.g. power and
control electronics for electric drive - J842- and control unit for
air conditioning compressor - V470- ). This causes the cooling
output of the air conditioner to increase and the pressure on
the low-pressure side and the evaporator temperature to drop.
If the required temperature value is then not reached at one
evaporator, the relevant control unit (e.g. the -J840- or -J255- )
actuates the integrated shut-off valves ( -N516- , -N541- , -
N517- or -N542- ) so that refrigerant no longer flows through
the evaporator which is too cold ⇒ Vehicle diagnostic tester
in “Guided Fault Finding” mode for air conditioner , ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations and
⇒ Heating, air conditioning; Rep. gr. 00 ; Repair instructions;
Checking the cooling output (vehicle-specific Workshop Man‐
ual).
♦ As the output of the evaporator for cooling the high-voltage
components (in the battery cooling module and in the high-
voltage battery heat exchanger) is considerably less than that
of the evaporator in the air conditioning unit, the required tem‐
perature may still be reached in the evaporator for cooling the
high-voltage components when there is insufficient refrigerant
in the circuit, but the required temperature will no longer be
reached at the evaporator in the air conditioning unit (although
the air conditioner compressor is being activated at a higher
speed).


fication
• High pressure remains con‐ ♦ Actuation of air conditioner compres‐ – Check actuation and opera‐
stant or only increases sor not OK ⇒ Vehicle diagnostic tester, tion of the air conditioner
slightly (above pressure “Guided Fault Finding” function for air compressor
with engine stopped) conditioner, air conditioner compres‐
sor and battery regulation . – Extract refrigerant from re‐
• Low pressure drops quickly frigerant circuit.
to specified value or below. ♦ Not enough refrigerant in circuit
• Required cooling output is ♦ Expansion valve for evaporator in air • If quantity of refrigerant ex‐
not attained in evaporator in conditioning unit defective. tracted is substantially less
air conditioning unit and in than specified capacity:
evaporator for cooling high- ♦ Shut-off valve upstream of evaporator – Locate leak with leak detec‐
voltage components. in air conditioning unit (e.g. -N516- or -
N541- , depending on vehicle) faulty tor and repair it.
(blocked) ⇒ Heating, air conditioning;
Rep. gr. 87 ; Refrigerant circuit (vehi‐ – Re-charge refrigerant circuit.
cle-specific Workshop Manual).
– Repeat test.
• High pressure normal • If amount of refrigerant ex‐
• Low pressure corresponds to specified capacity:
to specified value
– Shut-off valve upstream of
• Required cooling output is evaporator in air conditioning
not attained. unit (e.g. -N516- or -N541- ,
depending on vehicle) faulty
(blocked) ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Re‐
frigerant circuit (vehicle-spe‐
– Repeat test.
Note
Observe notes ⇒ page 225 .


fication
On vehicles without shut-off ♦ Actuation of air conditioner compres‐ – Extract refrigerant from re‐
valve upstream of evaporator sor not OK ⇒ Vehicle diagnostic tester, frigerant circuit.
in air conditioning unit (e.g. - “Guided Fault Finding” function for air
N516- or -N541- , depending conditioner, air conditioner compres‐ • If quantity of refrigerant ex‐
on vehicle) ⇒ Heating, air con‐ sor and battery regulation . tracted is substantially less
ditioning; Rep. gr. 87 ; Refrig‐ than specified capacity:
erant circuit (vehicle-specific ♦ Not enough refrigerant in circuit
Workshop Manual). – Locate leak with leak detec‐
♦ Expansion valve for evaporator in air tor and repair it.
• High pressure normal conditioning unit defective.
• low pressure too low (below – Re-charge refrigerant circuit.
specified value)
– Repeat test.
not attained at evaporator in • If amount of refrigerant ex‐
air conditioning unit. tracted roughly corresponds
– Renew expansion valve for
evaporator in air conditioning
unit.
– Repeat test.
On a vehicle with a shut-off ♦ Actuation of air conditioner compres‐ – Extract refrigerant from re‐
valve upstream of the evapo‐ sor not OK ⇒ Vehicle diagnostic tester, frigerant circuit.
rator in the air conditioning unit “Guided Fault Finding” function for air
(e.g. -N516- or -N541- (de‐ conditioner, air conditioner compres‐ • The quantity of refrigerant
pending on vehicle) ⇒ Heating, sor and battery regulation . extracted is much less than
air conditioning; Rep. gr. 87 ; the specified capacity (con‐
Refrigerant circuit (vehicle- ♦ Not enough refrigerant in circuit tinue in same way as a vehi‐
specific Workshop Manual). ♦ Expansion valve for evaporator in air cle without a shut-off valve
• High pressure normal conditioning unit defective. upstream of the evaporator
in the air conditioning unit)
• low pressure too low (below ♦ Shut-off valve upstream of the evapo‐
specified value) rator in the air conditioning unit (e.g. - • If amount of refrigerant ex‐
N516- or -N541- (depending on vehi‐ tracted roughly corresponds
• The required cooling output to specified capacity:
is not attained at the evap‐ cle) defective (closed) ⇒ Heating, air
orator in the air conditioning conditioning; Rep. gr. 87 ; Refrigerant – Check activation and opera‐
unit and at the evaporator circuit (vehicle-specific Workshop tion of shut-off valve up‐
for cooling the high-voltage Manual). stream of evaporator in air
components. conditioning unit (e.g. -N516-
or -N541- ) and shut-off valve
upstream of evaporator for
cooling high-voltage compo‐
nents (e.g. -N517- or -
N542- , depending on vehi‐
cle) ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Refrigerant
circuit (vehicle-specific
Workshop Manual).
– Renew expansion valve up‐

stream of evaporator in air
conditioning unit.
– Replace expansion valve (or

restrictor) upstream of the
evaporator for cooling the
high-voltage components.
– Repeat test.

Note

compressed air and nitrogen ⇒ page 84 ). Constriction or
blockage in the refrigerant circuit may also lead to one of these
problems.
♦ Depending on vehicle, check measured values of evaporator
output temperature sender - G263- and, if fitted, of tempera‐
ture sensor before evaporator for hybrid battery - G756- and
of temperature sensor after evaporator for hybrid battery -
G757- as well as activation of air conditioner compressor via
corresponding control units, e.g. control unit for air condition‐
ing compressor - J842- by battery regulation control unit -
J840- or by air conditioner operating and display unit
( Climatronic control unit - J255- ) ⇒ Vehicle diagnostic tester
regulation , ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
erant circuit (vehicle-specific Workshop Manual) and ⇒ Cur‐
rent flow diagrams, Electrical fault finding and Fitting locations.
♦ Incorrect measured values from -G263- (or e.g. -G756- / -
G757- ) can also cause problems with the cooling output, or
the evaporator in the air conditioning unit may ice up ⇒ Vehicle
diagnostic tester in “Guided Fault Finding” mode for air con‐
ditioner and battery regulation and ⇒ Heating, air conditioning;
Manual).
♦ If, e.g. after renewing the expansion valve, operation of the air
conditioning system is not OK when the test is repeated (re-fit
old expansion valve), clean the refrigerant circuit (flush with
refrigerant R134a ⇒ page 88 or blow out with compressed air
and nitrogen ⇒ page 84 ). Then renew the air conditioner com‐
pressor and receiver/desiccant cartridge.
♦ If a temperature sensor is faulty, the evaporator may ice up
although the quantity of refrigerant in the circuit is OK.
♦ If the expansion valve at the evaporator in the air conditioning
unit (or e.g. -N516- / -N541- , depending on vehicle) is defec‐
tive (i.e. is permanently closed or does not open sufficiently),
the air conditioner compressor is activated to maximum output
and the low pressure drops to the value in the graph or below
(air conditioner compressor draws off refrigerant from low-
pressure side). However, because no refrigerant can flow via
the expansion valve, the cooling output is not attained and the
high pressure may also not increase or only increase slightly
since there is no energy exchange ⇒ Vehicle diagnostic tester
erant circuit (vehicle-specific Workshop Manual) and ⇒ Heat‐
ing, air conditioning; Rep. gr. 00 ; Repair instructions;
Checking cooling output (vehicle-specific Workshop Manual).

♦ The evaporator in the air conditioning unit has a higher output

than the evaporator for cooling the high-voltage components
(e.g. in the battery cooling module or heat exchanger for high-
voltage battery, depending on vehicle). The shut-off valve (e.g.
refrigerant shut-off valve 2 for hybrid battery - N517- on the
expansion valve in the battery cooling module or refrigerant
shut-off valve for high-voltage battery heat exchanger -
N542- ) is activated by the battery regulation control unit - A2-
or air conditioner operating and display unit ( Climatronic
control unit - AX1- ) when the battery reaches or exceeds a
certain temperature, depending on the type of cooling used for
the drive battery - J840- / hybrid battery unit - J255- (hybrid
battery); energy exchange via the evaporator for cooling the
high-voltage components (in the battery cooling module or
heat exchanger for high-voltage battery) is not increased or
only slightly increased ⇒ Vehicle diagnostic tester in “Guided
Fault Finding” mode for air conditioner and battery regulation ,
(vehicle-specific Workshop Manual), and ⇒ Heating, air con‐
ditioning; Rep. gr. 00 ; Repair instructions; Checking cooling
output .

fication
On a vehicle with a shut-off ♦ Actuation of air conditioner compres‐ – Extract refrigerant from re‐
valve upstream of the evapo‐ sor not OK ⇒ Vehicle diagnostic tester, frigerant circuit.
rator in the air conditioning unit “Guided Fault Finding” function for air
(e.g. -N516- or -N541- (de‐ conditioner, air conditioner compres‐ • If the amount of refrigerant
pending on vehicle) ⇒ Heating, sor and battery regulation . extracted is significantly less
air conditioning; Rep. gr. 87 ; than the specified capacity:
Refrigerant circuit (vehicle- ♦ Not enough refrigerant in circuit
specific Workshop Manual). – Locate leak with leak detec‐
♦ Expansion valve for evaporator in air tor and repair it.
• High pressure normal conditioning unit defective.
• low pressure too low (below ♦ Shut-off valve upstream of the evapo‐ – Re-charge refrigerant circuit.
specified value) rator in the air conditioning unit (e.g. -
N516- or -N541- (depending on vehi‐ – Repeat test.
• The required cooling output
is not attained solely at the cle) defective (closed) ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant • If amount of refrigerant ex‐
evaporator in the air condi‐ tracted roughly corresponds
tioning unit (the cooling out‐ circuit (vehicle-specific Workshop
Manual). to specified capacity:
put is OK at the evaporator
for cooling the high-voltage – Check activation and opera‐
components). tion of shut-off valve (e.g. -
N516- or -N541- , depending
on vehicle); renew expan‐
sion valve at evaporator in air
conditioning unit if no fault is
found ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrig‐
erant circuit (vehicle-specific
Workshop Manual).
– Repeat test.


fication
• High pressure normal On vehicles with a battery cooling module – Check operation and activa‐
♦ Actuation or operation of refrigerant tion of the components for
• low pressure too low (below shut-off valve 2 for hybrid battery - cooling the high-voltage
specified value) N517- , of a control motor, blower or components ⇒ Vehicle diag‐
• The required cooling output temperature sensor in or at battery nostic tester in “Guided Fault
is not attained solely at the cooling module not OK. Finding” mode for air condi‐
evaporator for cooling the ♦ Constriction or blockage in the refrig‐ tioner, air conditioner com‐
high-voltage components pressor and battery regula‐
erant line to or from the expansion tion
(the cooling output is OK at valve at the battery cooling module
the evaporator in the air
conditioning unit). ♦ Expansion valve for evaporator for – Check refrigerant lines
cooling high-voltage components de‐
fective – Extract refrigerant from re‐
frigerant circuit.
♦ Not enough refrigerant in circuit
– Depending on vehicle, fit -
N517- in place of expansion
valve ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrig‐
erant circuit (vehicle-specific
Workshop Manual).
On vehicles with a heat exchanger for – Check restrictor in refriger‐
high-voltage battery ant line to heat exchanger for
♦ Activation or operation of shut-off valve high-voltage battery and
(e.g. refrigerant shut-off valve for high- clean or renew, if necessary.
voltage battery heat exchanger -
N542- , faulty refrigerant pump or fault – Re-charge refrigerant circuit.
in refrigerant circuit for high-voltage
components ⇒ Heating, air condition‐ – Repeat test.
ing; Rep. gr. 87 ; Refrigerant circuit
♦ Constriction or obstruction in the refrig‐
erant lines leading to or from the heat
exchanger for high-voltage battery
♦ Restrictor in the refrigerant line to the
heat exchanger for high-voltage bat‐
tery blocked
♦ Not enough refrigerant in circuit

Note
♦ On vehicles with battery cooling module, the refrigerant shut-

off valve 2 for hybrid battery - A2- is currently activated by the
battery regulation control unit - N517- in order to cool the drive
battery - J840- (hybrid battery) only when the battery reaches
a certain temperature. If air conditioning mode has not already
been activated at this point, the electrical air conditioner com‐
pressor - V470- is actuated via the control unit for air condi‐
tioning compressor - J842- by -J840- . The temperature of the
air upstream and downstream of the evaporator in the battery
cooling module is determined by -J840- . If it is established
that the cooling is not sufficient, this is stored in -J840- ⇒ Ve‐
hicle diagnostic tester in “Guided Fault Finding” mode for air
conditioner, air conditioner compressor and battery regulation
♦ On vehicles with a battery cooling module, the temperature of
the air (and thus the cooling output of the evaporator) in the
battery cooling module is determined by way of built-in tem‐
perature sensors (at present it cannot be measured with a
thermometer during operation) and can only be checked using
the Guided Fault Finding routine ⇒ Vehicle diagnostic tester,
“Guided Fault Finding” function for air conditioner, air condi‐
tioner compressor and battery regulation .
♦ On vehicles with a battery cooling module, observe additional
information ⇒ page 225 .
♦ On some vehicles with a heat exchanger for high-voltage bat‐
tery (e.g. Audi A3 e-tron; components may have a different
designation on other vehicles), the refrigerant shut-off valve
for high-voltage battery heat exchanger - A2- is no longer ac‐
tivated by the operating unit ( Climatronic control unit - J1050- )
above a certain temperature in order to cool the high-voltage
components, e.g. the drive battery - N542- and the high-volt‐
age battery charger control unit - J255- ( -N542- is open when
the system is de-energised. If air conditioning mode has not
already been activated at this point, the operating unit -V470-
actuates the electrical air conditioner compressor - J842- via
the control unit for air conditioning compressor - J255- . Other
components in this circuit must be actuated (e.g. refrigerant
circulation pump 2 - V178- and solenoid valve 1 - N88- ) and
the refrigerant must flow through the heat exchanger for high-
voltage battery to ensure that the refrigerant actually cools the
high-voltage components. If it is established that the cooling
of the high-voltage components is not sufficient, this is stored
in various control units ⇒ Vehicle diagnostic tester in “Guided
Fault Finding” mode for air conditioner, air conditioner com‐
pressor and battery regulation , ⇒ Heating, air conditioning;
Manual) and ⇒ Rep. gr. 19 ; Cooling system/coolant; Con‐
nection diagram - coolant hoses .
compressed air and nitrogen ⇒ page 84 ). Constriction or
blockage in the refrigerant circuit may also lead to one of these
problems.


cation
On a vehicle with ♦ Air conditioner – Check actuation
a shut-off valve compressor is not and operation of the
upstream of the activated or driv‐ air conditioner com‐
evaporator in the en. pressor and repair if
air conditioning necessary ⇒ Vehi‐
unit (e.g. -N516- ♦ Shut-off valve - cle diagnostic test‐
or -N541- (de‐ N516- or -N541- er, “Guided Fault
pending on vehi‐ (depending on Finding” function
cle) ⇒ Heating, vehicle) faulty for air conditioner
air conditioning; (blocked) ⇒ and battery regula‐
Rep. gr. 87 ; Re‐ Heating, air con‐ tion
frigerant circuit ditioning; Rep.
(vehicle-specific gr. 87 ; Refriger‐ – Check activation
Workshop Man‐ ant circuit (vehi‐ and operation of
ual). cle-specific shut-off valve (e.g. -
• High pres‐ Workshop Man‐ N516- or -N541- ,
sure does not ual). depending on vehi‐
rise or only cle); renew expan‐
rises slightly sion valve at evap‐
above the orator in air condi‐
pressure with tioning unit if no
the engine fault is found ⇒
stopped. Heating, air condi‐
tioning; Rep. gr.
• Low pressure 87 ; Refrigerant cir‐
does not drop cuit (vehicle-specif‐
or only drops ic Workshop Man‐
slightly. ual).
• Required
cooling out‐
put is not at‐
tained in
evaporator in
air condition‐
ing unit (and
in evaporator
for cooling
high-voltage
components)

frigerant circuit frigerant R134a
(e.g. in refrigerant ⇒ page 88 or blow
line between out with com‐
service connec‐ pressed air and ni‐
tion on low-pres‐ trogen ⇒ page 84 ).
sure side and air
conditioner com‐ – Renew hose or pipe
pressor). if kinked or constric‐
ted.
fective


ification
On a vehicle without a shut-off ♦ Activation or operation of air con‐ – Check actuation and operation of the
valve upstream of the evapo‐ ditioner compressor not OK air conditioner compressor and re‐
rator in the air conditioning pair if necessary ⇒ Vehicle diagnos‐
unit (e.g. -N516- or -N541- ♦ Constriction or blockage in refrig‐ tic tester, “Guided Fault Finding”
(depending on vehicle) ⇒ erant circuit function for air conditioner and bat‐
Heating, air conditioning; ♦ Expansion valve defective tery regulation
cuit (vehicle-specific Work‐ – Run hand over refrigerant circuit to
shop Manual). check for differences in temperature.
• High pressure increases
above specification • If there is a difference in temperature
at one component:
• Low pressure drops quick‐
ly to specified value – Renew hose or pipe if kinked or con‐
stricted.
not attained in evaporator – In the event of clogging, clean refrig‐
in air conditioning unit (and erant circuit (flush with refrigerant
in evaporator for cooling R134a ⇒ page 88 or blow out with
high-voltage components) compressed air and nitrogen
⇒ page 84 ).
– Repeat test.
• If operation is not OK and no fault is

found:
⇒ page 84 ).
– Repeat test if operation is not OK:
– Renew expansion valve upstream of

evaporator in air conditioning unit
and receiver.
On a vehicle with a shut-off ♦ Activation or operation of air con‐ – Check activation and operation of air
valve upstream of the evapo‐ ditioner compressor or shut-off conditioner compressor and shut-off
rator in the air conditioning valve (e.g. -N516- or -N541- , de‐ valves (e.g. -N516- ) ⇒ Vehicle di‐
unit (e.g. -N516- or -N541- pending on vehicle) faulty. ⇒ agnostic tester in “Guided Fault
(depending on vehicle) ⇒ Heating, air conditioning; Rep. Finding” mode for air conditioner and
Heating, air conditioning; gr. 87 ; Refrigerant circuit (vehi‐ battery regulation and ⇒ Heating, air
Rep. gr. 87 ; Refrigerant cir‐ cle-specific Workshop Manual). conditioning; Rep. gr. 87 ; Refriger‐
cuit (vehicle-specific Work‐ ant circuit (vehicle-specific Work‐
shop Manual). ♦ Constriction or blockage in refrig‐ shop Manual).
• High pressure increases erant circuit
above specification ♦ Expansion valve defective – Perform further testing as described
for vehicles without shut-off valve
• low pressure quickly drops upstream of evaporator.
to specified value,
not attained in evaporator
in air conditioning unit (and
in evaporator for cooling
high-voltage components)

Note
♦ If the operation of the air conditioner is not OK when the test

is repeated, renew the expansion valve and receiver (and -
N516- / -N541- if fitted) ⇒ Heating, air conditioning; Rep. gr.
♦ If the expansion valve at the evaporator in the air conditioning
unit or the shut-off valve (e.g. -N516- or -N541- ) is defective
(is permanently closed or does not open sufficiently), the air
conditioner compressor is activated to maximum output and
the low pressure drops to the specified value or below (air
conditioner compressor draws off refrigerant from low-pres‐
sure side). However, because no refrigerant (or only a small
amount) can flow via the expansion valve (the corresponding
shut-off valve), the cooling output is not attained and the high
there is no energy exchange ⇒ Vehicle diagnostic tester in
“Guided Fault Finding” mode for air conditioner and battery
♦ If a vehicle has a battery cooling module and the expansion
valve on the evaporator in the battery cooling module is de‐
fective (or refrigerant shut-off valve 2 for hybrid battery - N517-
is not operating or is not actuated properly), or if the expansion
valve is permanently closed or does not open sufficiently, the
air conditioner compressor is also actuated to maximum out‐
put (the required temperatures in the battery cooling module
are not reached). The pressure on the low-pressure side then
only drops to or below the specified value if no cooling output
is requested in the air conditioning unit at the same time (the
shut-off valve upstream of the evaporator in the air condition‐
ing unit, e.g. -N516- , is activated and closed). The air condi‐
tioner compressor draws off the refrigerant from the low-
pressure side of both evaporators. However, as no refrigerant
can flow via the expansion valve in the air conditioning unit
(e.g. -N516- ) and the cooling output is not reached in the bat‐
tery cooling module (fault in area of battery cooling module),
the electric air conditioner compressor is activated at a higher
speed. However, as no more refrigerant can flow, the pressure
on the low-pressure side drops below the specified value and
the high pressure may also not increase or only increase
nostic tester in “Guided Fault Finding” mode for air conditioner
and battery regulation , ⇒ Heating, air conditioning; Rep. gr.
and ⇒ Heating, air conditioning; Rep. gr. 00 ; Repair instruc‐
tions; Checking cooling output (vehicle-specific Workshop
Manual).

♦ On vehicles with a high-voltage battery heat exchanger, if the

restrictor installed in the refrigerant line to the high-voltage
battery heat exchanger is blocked or the shut-off valve (e.g.
refrigerant shut-off valve for high-voltage battery heat ex‐
changer - N542- on the Audi A3 e-tron) installed in this line is
faulty, permanently closed or does not open far enough, the
air conditioner compressor is also activated to maximum out‐
put (the required temperatures in the refrigerant circuit are not
reached with the high-voltage battery heat exchanger). The
pressure on the low-pressure side then only drops to or below
the specified value if no cooling output is requested in the air
conditioning unit at the same time ( -N541- is activated and
closed, e.g. on the Audi A3 e-tron). The air conditioner com‐
pressor draws off the refrigerant from the low-pressure side of
both evaporators. However, because refrigerant cannot flow
via the expansion valve into the air conditioning unit (via the
shut-off valve, e.g. -N541- ) and the cooling output in the high-
voltage battery heat exchanger is not reached, the electric air
conditioner compressor is activated at a higher speed. How‐
ever, as no more refrigerant can flow, the pressure on the low-
pressure side drops below the specified value and the high
there is no energy exchange ⇒ Vehicle diagnostic tester in
“Guided Fault Finding” mode for air conditioner and battery
The same applies if a fault occurs in the coolant circuit where
the high-voltage battery heat exchanger is installed (e.g. cool‐
ant circulation pump 2 - V178- or solenoid valve 1 - N88- (on
Audi A3 e-tron) are not activated correctly or are faulty). Al‐
though the high-voltage battery heat exchanger is cooled, the
coolant does not reach the high-voltage components which
need to be cooled ⇒ Heating, air conditioning; Rep. gr. 87 ;
Coolant circuit (vehicle-specific Workshop Manual) and ⇒
Rep. gr. 19 ; Cooling system/coolant; Connection diagram -
coolant hoses .
♦ As the cooling output of the evaporator for cooling the high-
voltage battery is less than that of the evaporator in the air
conditioning unit, the required temperature in the evaporator
for cooling the high-voltage battery may still be reached when
there is not enough refrigerant in the circuit, but the required
temperature will no longer be reached at the evaporator in the
air conditioning unit (although the air conditioner compressor
is activated at a higher speed).
♦ If there is too much refrigerant oil in the circuit, also discharge
(flush) the air conditioner compressor and renew the receiver/
desiccant cartridge. After cleaning the refrigerant circuit (flush‐
ing with refrigerant R134a ⇒ page 88 or blowing out with
compressed air and nitrogen ⇒ page 84 ), add the correct
amount of refrigerant oil to the circuit (to the air conditioner
compressor) ⇒ page 317 .


fication
• High and low pressure nor‐ ♦ Activation or operation of air condition‐ – Check activation of air con‐
mal at first, but after a while: er compressor or shut-off valve (e.g. - ditioner compressor and
N516- or -N541- , depending on vehi‐ shut-off valve (e.g. -N516- or
• High pressure rises above cle) faulty ⇒ Heating, air conditioning; -N541- ) ⇒ Vehicle diagnos‐
specified value Rep. gr. 87 ; Refrigerant circuit (vehi‐ tic tester in “Guided Fault
• Low pressure drops to cle-specific Workshop Manual). Finding” mode for air condi‐
specified value or below tioner and battery regula‐
♦ Moisture in refrigerant circuit tion .
not attained in evaporator in – Clean refrigerant circuit
air conditioning unit (and in (flush with refrigerant R134a
evaporator for cooling high- ⇒ page 88 or blow out with
voltage components) compressed air and nitrogen
⇒ page 84 ).
• High and low pressure nor‐ – Renew receiver with dryer.
mal at first
• After driving for a while, low for at least 3 hours.
pressure drops below
specified value (evaporator – Re-charge refrigerant circuit.
in air conditioning unit ices
up) – Repeat test.
Note

♦ A faulty evaporator output temperature sender - G263- and/
or, if fitted, temperature sensor after evaporator for hybrid bat‐
tery - G757- (depending on vehicle) may also cause the re‐
frigerant circuit to ice up. If this problem occurs, also observe
the measured value for -G263- and -G757- (e.g. on vehicles
with a battery cooling module) ⇒ Vehicle diagnostic tester; in
“Guided Fault Finding” mode for air conditioner, ⇒ Heating,
cific Workshop Manual) and ⇒ Heating, air conditioning; Rep.
gr. 00 ; Repair instructions; Checking cooling output (vehicle-


fication
• High pressure normal ♦ Activation or operation of air condition‐ – Check activation and opera‐
er compressor or, if fitted, shut-off tion of air conditioner com‐
• Low pressure too low valves (e.g. -N516- , -N517- , -N541- or pressor and, if fitted, shut-off
• Required cooling output is -N542- , depending on vehicle) faulty valves (e.g. -N516- and -
not attained in evaporator in ⇒ Heating, air conditioning; Rep. gr. N517- ) ⇒ Vehicle diagnostic
air conditioning unit (and in 87 ; Refrigerant circuit (vehicle-specific tester in “Guided Fault Find‐
evaporator for cooling high- Workshop Manual). ing” mode for air conditioner
voltage components) and battery regulation and ⇒
♦ Expansion valve in air conditioning unit Heating, air conditioning;
or, if fitted, in battery cooling module Rep. gr. 87 ; Refrigerant cir‐
defective. cuit (vehicle-specific Work‐
♦ Expansion valve in the air conditioning shop Manual).
unit faulty or restrictor in the refrigerant
line to the heat exchanger for high-volt‐ – Clean refrigerant circuit
age battery blocked (if available). (flush with refrigerant R134a
♦ Air conditioner compressor defective compressed air and nitrogen
⇒ page 84 ) (not always nec‐
essary, refer to notes).

unit and for receiver/dryer.
– If fitted, renew expansion

valve for evaporator in bat‐
tery cooling module or clean/
renew refrigerant line with re‐
strictor to the heat exchanger
for high-voltage battery.

OK:

pressor.

– Repeat test.

Note
♦ If the fault “High pressure normal, low pressure too low” oc‐
curs, please note that the evaporator in the air conditioning
unit may ice up although the amount of refrigerant in the circuit
is OK.
♦ If the problem is with the air conditioner compressor (the air
conditioner compressor is actuated at excessively high speed
by the air conditioner compressor regulating valve - J842- ),
the refrigerant circuit does not have to be cleaned (by flushing
with refrigerant R134a ⇒ page 88 or blowing out with com‐
pressed air and nitrogen ⇒ page 84 ). In this case it is sufficient
to renew the air conditioner compressor (observe quantity of
refrigerant oil in compressor and adjust if necessary).
♦ On vehicles with a battery cooling module, if the expansion
valve for the evaporator in the air conditioning unit or the ex‐
pansion valve for the evaporator in the battery cooling module
is defective (permanently closed or does not open sufficiently),
the air conditioner compressor is also actuated to maximum
output and the pressure on the low-pressure side drops to the
value in the graph or below (the air conditioner compressor
draws off refrigerant from the low-pressure side). As refriger‐
ant cannot however flow via the defective expansion valve, the
cooling output is not attained in the downstream evaporator
and the high pressure may either not increase or only increase
slightly due to the absence of energy conversion. However,
the air conditioner compressor may be activated at a higher
speed, as the required cooling output is not attained in one
evaporator. This also applies if operation or activation of a
shut-off valve (e.g. refrigerant shut-off valve 1 for hybrid bat‐
tery - N516- or refrigerant shut-off valve 2 for hybrid battery -
N517- , depending on vehicle) is not OK ⇒ Vehicle diagnostic
tester; in “Guided Fault Finding” mode for air conditioner, ⇒
hicle-specific Workshop Manual) and ⇒ Heating, air condi‐
tioning; Rep. gr. 00 ; Repair instructions; Checking cooling
output (vehicle-specific Workshop Manual).
expansion valve for the evaporator in the air conditioning unit
is defective (permanently closed or does not open far enough)
or the restrictor in the refrigerant line to the high-voltage bat‐
tery heat exchanger is blocked, the air conditioner compressor
is also activated to maximum output and the pressure on the
low-pressure side drops to the value in the graph or below (the
pressure side). However, as refrigerant cannot flow via the
defective expansion valve or blocked restrictor, the cooling
output is not attained in the downstream evaporator and the
high pressure may either not increase or only increase slightly
since there is no energy exchange. However, the air condi‐
tioner compressor may be activated at a higher speed, as the
required cooling output is not attained in one evaporator. This
also applies if operation or activation of a shut-off valve (e.g.
refrigerant shut-off valve for heater and air conditioner unit -
N541- or refrigerant shut-off valve for high-voltage battery heat
exchanger - N542- , depending on vehicle) or a component
installed in the refrigerant circuit for high-voltage components
(e.g. coolant circulation pump 2 - V178- or solenoid valve 1 -
N88- on Audi A3 e-tron, depending on vehicle) is not OK
⇒ Vehicle diagnostic tester; in “Guided Fault Finding” mode for
air conditioner, ⇒ Rep. gr. 19 ; Cooling system/coolant; Con‐
nection diagram - coolant hoses and ⇒ Heating, air condi‐
Workshop Manual).

♦ Check the measured values for the evaporator output tem‐

perature sender - G263- (and if applicable the measured
values for the temperature sensor before evaporator for hybrid
battery - G756- and temperature sensor after evaporator for
hybrid battery - G757- , depending on vehicle) as well as ac‐
tivation of the air conditioner compressor by the battery regu‐
lation control unit - J840- , the air conditioner operating unit
( Climatronic control unit - J255- ) / operating and display unit
for front air conditioning system - E87- or thermal management
control unit - J1024- (depending on vehicle). If the measured
value of -G263- (or -G756- / -G757- , depending on vehicle)
or activation of the air conditioner compressor is not OK, the
evaporator may ice up or the required cooling output is not
attained ⇒ Vehicle diagnostic tester; in “Guided Fault Finding”
mode for air conditioner, ⇒ Heating, air conditioning; Rep. gr.
Manual).


fication
• High pressure normal or too ♦ Activation or operation of air condition‐ – Check activation and opera‐
high er compressor not OK tion of air conditioner com‐
pressor and, if fitted, these
• Low pressure too high ♦ Depending on refrigerant circuit ver‐ shut-off valves ( -N516- , -
sion, activation or operation of one of N517- , -N541- and -N542- ,
• Noise from air conditioner these shut-off valves ( -N516- , -N517- ,
compressor (particularly af‐ depending on vehicle) ⇒ Ve‐
-N541- or -N542- , depending on vehi‐ hicle diagnostic tester in
ter being switched on) cle) is not OK ⇒ Heating, air condition‐ “Guided Fault Finding” mode
• The required cooling output ing; Rep. gr. 87 ; Refrigerant circuit for air conditioner and bat‐
is not attained in the evap‐ (vehicle-specific Workshop Manual). tery regulation and ⇒ Heat‐
orator in the air conditioning ♦ Too much refrigerant in circuit ing, air conditioning; Rep. gr.
unit and / or in the evapora‐ 87 ; Refrigerant circuit (vehi‐
tor for cooling the high-volt‐ ♦ Expansion valve defective cle-specific Workshop Man‐
age components. ual).
♦ Air conditioner compressor defective
– Extract refrigerant from re‐
frigerant circuit.
• The quantity of refrigerant

extracted corresponds
ty.
unit and for receiver/dryer.
– Renew expansion valve with

-N517- .
– Check restrictor in refriger‐

ant line to heat exchanger for
high-voltage battery and
clean or renew, if necessary.

OK.
pressor.

– Repeat test.

Note

♦ On vehicles with a battery cooling module, if the expansion
valve for the evaporator in the air conditioning unit or the ex‐
pansion valve for the evaporator in the battery cooling module
is defective (permanently closed or does not open sufficiently),
the air conditioner compressor is also actuated to maximum
output and the pressure on the low-pressure side drops to the
value in the graph or below (the air conditioner compressor
draws off refrigerant from the low-pressure side). As refriger‐
ant cannot however flow via the defective expansion valve, the
cooling output is not attained in the downstream evaporator
and the high pressure may either not increase or only increase
slightly due to the absence of energy conversion. However,
the air conditioner compressor may be activated at a higher
speed, as the required cooling output is not attained in one
evaporator. This also applies if operation or activation of a
shut-off valve (e.g. refrigerant shut-off valve 1 for hybrid bat‐
tery - N516- or refrigerant shut-off valve 2 for hybrid battery -
N517- , depending on vehicle) is not OK ⇒ Vehicle diagnostic
tester; in “Guided Fault Finding” mode for air conditioner and
expansion valve for the evaporator in the air conditioning unit
is defective (permanently closed or does not open far enough)
or the restrictor in the refrigerant line to the high-voltage bat‐
tery heat exchanger is blocked, the air conditioner compressor
is also activated to maximum output and the pressure on the
low-pressure side drops to the value in the graph or below (the
pressure side). However, as refrigerant cannot flow via the
defective expansion valve or blocked restrictor, the cooling
output is not attained in the downstream evaporator and the
high pressure may either not increase or only increase slightly
since there is no energy exchange. However, the air condi‐
tioner compressor may be activated at a higher speed, as the
required cooling output is not attained in one evaporator. This
also applies if operation or activation of refrigerant shut-off
valve for heater and air conditioner unit - N541- , refrigerant
shut-off valve for high-voltage battery heat exchanger - N542-
(e.g. on Audi A3 e-tron) or a component installed in the refrig‐
erant circuit for high-voltage components (e.g. coolant circu‐
lation pump 2 - V178- or solenoid valve 1 - N88- on Audi A3
e-tron) is not OK ⇒ Vehicle diagnostic tester; in “Guided Fault
Finding” mode for air conditioner, ⇒ Rep. gr. 19 ; Cooling
system/coolant; Connection diagram - coolant hoses and ⇒


fication
• High and low pressure nor‐ ♦ Activation or operation of air condition‐ – Check activation and opera‐
mal er compressor not OK tion of air conditioner com‐
pressor and, if fitted, these
• Required cooling output is ♦ Depending on refrigerant circuit ver‐ shut-off valves (e.g. -N516- ,
not attained in evaporator in sion, activation or operation of one of -N517- , -N541- and -N542- )
air conditioning unit (and in these shut-off valves (e.g. -N516- , - ⇒ Vehicle diagnostic tester
evaporator for cooling high- N517- , -N541- or -N542- , depending in “Guided Fault Finding”
voltage components) on vehicle) is not OK ⇒ Heating, air mode for air conditioner and
conditioning; Rep. gr. 87 ; Refrigerant battery regulation and ⇒
circuit (vehicle-specific Workshop Heating, air conditioning;
Manual). Rep. gr. 87 ; Refrigerant cir‐
♦ Too much refrigerant in circuit cuit (vehicle-specific Work‐
shop Manual).

⇒ page 84 ).
• High and low pressure nor‐ – Add correct quantity of refrig‐
mal erant oil to circuit (refer to
note).
compressor (particularly af‐ – Re-charge refrigerant circuit.
ter being switched on)
• Required cooling output is – Repeat test if operation is not
not attained in evaporator in OK:
air conditioning unit (and/or
in evaporator for cooling – Renew expansion valve.
– Repeat test.
Note
♦ If for example the expansion valve for the evaporator in the air
conditioning unit is defective (permanently open), the evapo‐
rator temperature (in the air conditioning unit) is no longer
regulated such that only refrigerant in gas form exits from the
evaporator. Under certain usage conditions, liquid droplets
may then be drawn in by the air conditioner compressor and
result in noise (liquid cannot be compressed).
cleaning the refrigerant circuit (flushing with refrigerant R134a


ant circuit on vehicles with heat pump
Note
♦ On vehicles with high-voltage system and heat pump (e.g.

Audi Q7 e-tron), non-return valves and electrically activated
valves are installed in the refrigerant circuit which regulate the
flow of refrigerant in the refrigerant circuit depending on the
current operating mode. There are different versions of these
valves ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit (vehicle-specific Workshop Manual) and ⇒ Vehicle di‐
agnostic tester in “Guided Fault Finding” mode.
♦ On vehicles with the “heat pump” and/or “high-voltage battery
connection on the high-pressure side in all air conditioner op‐
erating modes. On these vehicles, the pressure in the refrig‐
erant circuit on the high-pressure side can only be measured
via the pressure/temperature senders installed in the refriger‐
ant circuit (depending on the air conditioner operating mode)
(vehicle-specific Workshop Manual) and ⇒ Vehicle diagnostic
tester (“Guided Fault Finding”).
♦ On these vehicles, the air conditioning system's refrigerant
circuit is used not only to cool the passenger compartment but
also to cool the hybrid battery unit - AX1- (via the high-voltage
system's coolant circuit) and heat the passenger compartment
via the heat pump function when ambient temperatures are
low. To operate these functions, various valves, pressure/
temperature senders and pumps in the refrigerant circuit and
the high-voltage system's coolant circuit must be correctly in‐
stalled and working properly ⇒ Heating, air conditioning; Rep.
ual), ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
mode and ⇒ Engine, mechanics; Rep. gr. 19 ; Cooling sys‐
tem/coolant; Draining and filling cooling system .
♦ To locate the possible cause of a malfunction, various routines
have been stored in the basic setting of -J1024- ; these rou‐
tines activate the “Air conditioner cooling”, “Heat pump” and
“Cooling of high-voltage system components” functions ⇒ Ve‐
hicle diagnostic tester (“Guided Fault Finding”).
High-pressure side:
Note
Depending on the layout of the service connection (high-pressure

side) and on the operating mode, it may only be possible to meas‐
ure the high pressure via the pressure/temperature senders in‐
stalled in the refrigerant circuit ⇒ Heating, air conditioning; Rep.
Low-pressure side:
Dropping from initial pressure (when connecting pressure
gauges) to a value between 1.5 and 2.3 bar absolute (depending
on cooling output required)

Air conditioner compressor speed:

Between 800 and 8600 rpm depending on cooling output required
(currently max. 5000 rpm with vehicle stationary)

Note
♦ The temperature of the air downstream of the evaporator, the

current air conditioner compressor speed and the refrigerant
pressure on the high-pressure side are displayed as meas‐
ured values by various control units depending on the vehicle
(e.g. by the thermal management control unit - J1024- , oper‐
ating and display unit for front air conditioning system - E87-
or Climatronic control unit - J255- ) ⇒ Heating, air conditioning;
Manual), and ⇒ Vehicle diagnostic tester in “Guided Fault
Finding” mode.
♦ If a very high cooling output is required (e.g. high ambient
temperature and high fresh air blower speed), the air condi‐
tioner compressor cannot initially set the pressure on the low-
pressure side to the necessary value (e.g. for a certain time
after switching on the air conditioner). When the vehicle is sta‐
tionary or only moving slowly (up to a speed of approx. 45 km/
h), the air conditioner compressor is not activated at the max‐
imum specified speed (of approx. 8500 rpm); the air condi‐
tioner compressor speed is limited to approx. 5000 rpm.
Limitation of the maximum permissible air conditioner com‐
pressor speed is only cancelled at vehicle speeds above
approx. 45 km/h. At an air conditioner compressor speed of
5000 rpm, with a high ambient temperature and a high fresh
air blower speed (unfavourable ambient conditions), the out‐
put (delivery volume) of the air conditioner compressor is not
initially sufficient to reduce the pressure on the low-pressure
side to the specified value. One way of checking the control
action of the air conditioner compressor under these condi‐
tions is to activate the fresh air blower with only approx. 40 %
of the maximum voltage and to check the pressures at reduced
fresh air blower speed ⇒ Vehicle diagnostic tester in “Guided
Fault Finding” mode for air conditioner and battery regulation,
Manual).
♦ The specified speed of the air conditioner compressor is dis‐
played as a measured value e.g. by thermal management
control unit - J1024- ⇒ Vehicle diagnostic tester in “Guided
♦ The pressure (low or high pressure) in the refrigerant circuit,
as measured by the various pressure/temperature senders
depending on the corresponding operating mode, is displayed
as a measured value by the corresponding control unit ⇒ Ve‐
hicle diagnostic tester in “Guided Fault Finding” mode and ⇒
♦ Depending on the air conditioner compressor speed and the
characteristic curve of the expansion valve (on the evaporator
for the front heater and air conditioning unit), the low pressure
settles within the air conditioner compressor output range in
the tolerance band (1.5 to 2.3 bar).
♦ The specified air conditioner compressor speed must be high‐
er than 1500 rpm for this test.
♦ In the “maximum cooling output” setting, the specified speed
is regulated to approx. 4000 to 5000 rpm. This value is vehicle-
specific and is displayed as a measured value by the corre‐
sponding control unit ⇒ Vehicle diagnostic tester in “Guided


absolute pressure of 1 bar. 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).
♦ On vehicles with 2 evaporators (one in the heater and air con‐
ditioning unit and one for cooling the high-voltage compo‐
nents, e.g. the high-voltage battery heat exchanger) and 2
condensers (one on the front end for the air conditioner and
one as a heat exchanger for the heat pump function): If the
measured temperatures or pressures correspond to the spec‐
ifications for one component but not for another component
(depending on the selected function), check the activation of
the electrically activated valves installed in the refrigerant cir‐
cuit. Also observe the pressure distribution in the refrigerant
circuit (depending on the non-return valves installed) ⇒ Vehi‐
cle diagnostic tester in “Guided Fault Finding” mode and ⇒
♦ For correct operation of the air conditioner, it is also necessary
for sufficient heat to be supplied to or discharged from the cor‐
responding heat exchangers (depending on the selected func‐
tion). You should therefore also pay attention to the incorpo‐
ration of the heat exchanger into the corresponding coolant
circuits for the engine and for the high-voltage system, and to
the operation of the pumps and valves installed in these ⇒ Ve‐
♦ As the output of the evaporator for cooling the high-voltage
components (in the battery cooling module and in the high-
voltage battery heat exchanger) is less than that of the evap‐
orator in the heater and air conditioning unit, the required
temperature may still be reached in the evaporator for cooling
the high-voltage components when there is insufficient refrig‐
erant in the circuit, but the required temperature will no longer
be reached at the evaporator in the heater and air conditioning
unit (although the air conditioner compressor is being activa‐
ted at a higher speed).

fication
• High pressure remains con‐ ♦ Not enough refrigerant in circuit – Extract refrigerant from re‐
stant or only increases frigerant circuit.
slightly (above pressure
with engine stopped) • If quantity of refrigerant ex‐
tracted is substantially less
• Low pressure drops quickly than specified capacity:
to specified value or below.
– Locate leak with leak detec‐
• Required cooling output is tor and repair it.
not attained in evaporator in
air conditioning unit and in – Re-charge refrigerant circuit.
evaporator for cooling high-
voltage components. – Repeat test.
• If amount of refrigerant ex‐
– Check activation and opera‐
tion of air conditioner com‐
pressor and of valves instal‐
led in refrigerant circuit (see
below).


fication
♦ Activation of air conditioner compres‐ – Check activation and opera‐
sor not OK tion of air conditioner com‐
pressor ⇒ Vehicle diagnostic
tester in “Guided Fault Find‐
ing” mode
• High pressure normal ♦ One of the valves installed in the re‐ – Check operation and activa‐
frigerant circuit is defective or does not tion of the various valves in‐
• Low pressure corresponds function properly ⇒ Heating, air condi‐ stalled in refrigerant circuit
to specified value tioning; Rep. gr. 87 ; Refrigerant circuit by observing pressure distri‐
• Required cooling output is (vehicle-specific Workshop Manual). bution in refrigerant circuit
not attained. ⇒ Vehicle diagnostic tester in
“Guided Fault Finding” mode
and ⇒ Heating, air condition‐
Workshop Manual).
♦ Not enough refrigerant in circuit – Discharge and refill refriger‐
ant circuit (see above).
♦ Shut-off valve upstream of expansion
valve for evaporator in front heater and – Repeat test.
air conditioning unit defective
♦ Expansion valve for evaporator in front – Check shut-off valve ⇒ Heat‐
heater and air conditioning unit defec‐ ing, air conditioning; Rep. gr.
tive 87 ; Refrigerant circuit (vehi‐
cle-specific Workshop Man‐
ual).

Note
♦ To locate the possible cause of a malfunction, various routines

have been stored in the basic setting of the corresponding
control unit (e.g. -J1024- ); these routines activate the “Air
conditioner cooling”, “Heat pump” and “Cooling of high-voltage
system components” functions ⇒ Vehicle diagnostic tester in
♦ If no fault is detected for this issue, first check the activation of
the electrically activated valves installed in the refrigerant cir‐
cuit. If no fault can be detected, remove and check the non-
return valves installed in the refrigerant circuit; if it is still not
possible to detect a fault, clean the refrigerant circuit (with re‐
frigerant R134a); the issue may alternatively have been
caused by a constriction or blockage in the refrigerant circuit
(vehicle-specific Workshop Manual) and ⇒ page 88 .
♦ On vehicles with the “heat pump” and/or “high-voltage battery
connection on the high-pressure side in all air conditioner op‐
erating modes. On these vehicles, the pressure in the refrig‐
erant circuit on the high-pressure side can only be measured
via the pressure/temperature senders installed in the refriger‐
ant circuit (depending on the air conditioner operating mode)
(vehicle-specific Workshop Manual) and ⇒ Vehicle diagnostic
tester (“Guided Fault Finding”).
♦ Before starting repair work, also check the measured values
of the various pressure/temperature senders installed in the
refrigerant circuit. An incorrect measured value from a pres‐
sure/temperature sender can also cause problems with the
cooling output, or the evaporator in the front heater and air
conditioning unit may ice up ⇒ Heating, air conditioning; Rep.
ual), ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
mode and ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
♦ When checking the various functions (heat pump or high-volt‐
age battery cooling), also observe the activation and operation
of the coolant circuit components associated with these func‐
tions ⇒ Heating, air conditioning; Rep. gr. 87 ; Coolant circuit
♦ If the test is repeated and operation of the air conditioner is not
OK, e.g. after renewing the expansion valve (re-fit old expan‐
sion valve), clean the refrigerant circuit (flush with refrigerant
R134a ⇒ page 88 ). Then renew the air conditioner compres‐
sor and receiver/desiccant cartridge.
♦ If a temperature sensor is faulty, the evaporator may ice up
although the quantity of refrigerant in the circuit is OK.
♦ If the expansion valve at the evaporator in the heater and air
conditioning unit is defective (is permanently closed or does
not open far enough), the air conditioner compressor is acti‐
vated to maximum output and the low pressure drops to the
value in the graph or below (air conditioner compressor draws
off refrigerant from low-pressure side). However, as refrigerant
cannot flow via the expansion valve, the cooling output is not
attained and the high pressure may also not increase or only
increase slightly since there is no energy exchange ⇒ Vehicle
diagnostic tester in “Guided Fault Finding” mode and ⇒ Heat‐
ing, air conditioning; Rep. gr. 00 ; Repair instructions; Check‐
ing cooling output (vehicle-specific Workshop Manual).

♦ The evaporator in the heater and air conditioning unit has a

higher output than the evaporator for cooling the high-voltage
components. Depending on the version, the expansion valve
upstream of this evaporator (the heat exchanger for cooling
the high-voltage system components) is currently activated by
the corresponding control unit in order to cool the drive battery
- A2- / hybrid battery unit - AX1- (hybrid battery) only above/
below a certain battery temperature, which means that energy
exchange via this evaporator does not rise or only rises slightly
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode
Manual).
♦ If there is too much refrigerant oil in the circuit, also discharge
(flush) the air conditioner compressor and renew the receiver/
desiccant cartridge. After cleaning the refrigerant circuit (flush‐
ing with refrigerant R134a ⇒ page 88 ), add the correct amount
of refrigerant oil to the circuit (to the air conditioner compres‐
sor) ⇒ page 317 .

fication
• High pressure normal ♦ Not enough refrigerant in circuit – Extract refrigerant from re‐
frigerant circuit.
• Low pressure normal or too
low (below specified value) • If the amount of refrigerant
• The required cooling output extracted is significantly less
is not attained solely at the than the specified capacity:
evaporator in the air condi‐ – Locate leak with leak detec‐
tioning unit (the cooling out‐ tor and repair it.
put is OK at the evaporator
for cooling the high-voltage – Re-charge refrigerant circuit.
components).
– Repeat test.
• If amount of refrigerant ex‐

below).
♦ Activation of air conditioner compres‐ – Check activation and opera‐
sor faulty ⇒ Vehicle diagnostic tester in tion of air conditioner com‐
“Guided Fault Finding” mode pressor ⇒ Vehicle diagnostic
♦ Expansion valve for evaporator in front ing” mode
heater and air conditioning unit defec‐
tive
♦ One of the valves installed in the re‐ – Check operation and activa‐
function properly ⇒ Heating, air condi‐ stalled in refrigerant circuit
tioning; Rep. gr. 87 ; Refrigerant circuit by observing pressure distri‐
(vehicle-specific Workshop Manual). bution in refrigerant circuit
⇒ Vehicle diagnostic tester in
Workshop Manual).


fication
♦ Shut-off valve upstream of expansion – Check shut-off valve ⇒ Heat‐
valve for evaporator in front heater and ing, air conditioning; Rep. gr.
air conditioning unit defective 87 ; Refrigerant circuit (vehi‐
♦ Expansion valve for evaporator in front ual).
tive – Renew expansion valve
– Repeat test.
Note

fication
• High pressure normal ♦ One of the valves installed in the re‐ – Check operation and activa‐
• Low pressure normal or too function properly ⇒ Heating, air condi‐ stalled in refrigerant circuit
low (below specified value) tioning; Rep. gr. 87 ; Refrigerant circuit by observing pressure distri‐
• The required cooling output (vehicle-specific Workshop Manual). bution in refrigerant circuit
is not attained solely at the ♦ One of the pumps or valves in the high- ⇒ Vehicle diagnostic tester in
evaporator for cooling the “Guided Fault Finding” mode
voltage system's coolant circuit is de‐ and ⇒ Heating, air condition‐
high-voltage components fective or does not function properly ⇒
(the cooling output is OK at ing; Rep. gr. 87 ; Refrigerant
Heating, air conditioning; Rep. gr. 87 ; circuit (vehicle-specific
the evaporator in the front Coolant circuit (vehicle-specific Work‐
heater and air conditioning Workshop Manual).
shop Manual).
unit).
– Check operation and activa‐
tion of components for cool‐
ing high-voltage compo‐
nents ⇒ Vehicle diagnostic
tester (“Guided Fault Find‐
ing”).
♦ Constriction or blockage in refrigerant – Extract refrigerant from re‐
line to or from expansion valve at evap‐ frigerant circuit.
orator for cooling high-voltage compo‐
nents – Check refrigerant line to ex‐
pansion valve and clean or
♦ Expansion valve for evaporator for renew if necessary.
cooling high-voltage components de‐
fective – Re-charge refrigerant circuit.
– Repeat test.
Note


cation
• High pres‐ ♦ Air conditioner – Check activation
sure does not compressor is not and operation of air
rise or only activated or driv‐ conditioner com‐
rises slightly en. pressor and per‐
above the form servicing
pressure with ♦ One of the valves ⇒ Vehicle diagnos‐
the engine installed in the re‐ tic tester in “Guided
stopped. frigerant circuit is Fault Finding”
defective or does mode.
• Low pressure not function prop‐
does not drop erly ⇒ Heating, – Check operation
or only drops air conditioning; and activation of
slightly. Rep. gr. 87 ; Re‐ the various valves
frigerant circuit installed in refriger‐
• Required (vehicle-specific
cooling out‐ ant circuit by ob‐
Workshop Man‐ serving pressure
put is not at‐ ual).
tained in distribution in refrig‐
evaporator in erant circuit ⇒ Vehi‐
air condition‐ cle diagnostic test‐
ing unit (and er in “Guided Fault
in evaporator Finding” mode and
for cooling ⇒ Heating, air con‐
high-voltage ditioning; Rep. gr.
components) 87 ; Refrigerant cir‐
cuit (vehicle-specif‐
ic Workshop Man‐
ual).
frigerant circuit frigerant R134a)
(e.g. in refrigerant ⇒ page 88 .
line between
service connec‐ – Renew hose or pipe
tion on low-pres‐ if kinked or constric‐
sure side and air ted.
conditioner com‐
pressor).

fective
Note


ification
• High pressure increases ♦ Activation or operation of air con‐ – Check activation and operation of air
above specification ditioner compressor not OK conditioner compressor and perform
servicing ⇒ Vehicle diagnostic tester
• Low pressure drops quick‐ ♦ One of the valves installed in the in “Guided Fault Finding” mode.
ly to specified value refrigerant circuit is defective or
does not function properly ⇒ – Check operation and activation of
• Required cooling output is Heating, air conditioning; Rep.
not attained in evaporator the various valves installed in refrig‐
gr. 87 ; Refrigerant circuit (vehi‐ erant circuit by observing pressure
in front heater and air con‐ cle-specific Workshop Manual).
ditioning unit (and/or in distribution in refrigerant circuit
evaporator for cooling ♦ Constriction or blockage in refrig‐ ⇒ Vehicle diagnostic tester in “Gui‐
high-voltage components) erant circuit ded Fault Finding” mode and ⇒
Heating, air conditioning; Rep. gr.
♦ Expansion valve defective 87 ; Refrigerant circuit (vehicle-spe‐
– Run hand over refrigerant circuit to
check for differences in temperature.

at one component:
stricted.
– In the event of a blockage, clean re‐

frigerant circuit (flush with refrigerant
R134a ⇒ page 88 ).
– Repeat test.

Note

♦ If the expansion valve at the evaporator in the heater and air
conditioning unit or the shut-off valve installed upstream is de‐
fective (is permanently closed or does not open sufficiently),
the air conditioner compressor is activated to maximum output
and the low pressure drops to the specified value or below (air
conditioner compressor draws off refrigerant from low-pres‐
sure side). However, as no refrigerant (or an insufficient
amount) can flow via the expansion valve, the cooling output
is not attained and the high pressure may also not increase or
only increase slightly since there is no energy exchange ⇒ Ve‐
♦ If the expansion valve upstream of the evaporator for cooling
the high-voltage components is defective (or its operation or
activation is faulty), permanently closed or does not open suf‐
ficiently, the air conditioner compressor is also activated to
maximum output (the required temperatures in the heat ex‐
changer are not reached). The pressure on the low-pressure
side then only drops to or below the specified value if no cool‐
ing output is requested in the front heater and air conditioning
unit at the same time. The air conditioner compressor draws
off the refrigerant from the low-pressure side of both evapo‐
rators. However, as no refrigerant can flow via the expansion
valve in the front heater and air conditioning unit, and the cool‐
ing output is not reached in the evaporator for cooling the high-
voltage components (there is a fault in the area of the
evaporator for cooling the high-voltage components), the elec‐
tric air conditioner compressor is activated at a higher speed.
However, as no more refrigerant can flow, the pressure on the
low-pressure side drops below the specified value and the
since there is no energy exchange. The same applies if a valve
in the refrigerant circuit is not OK, if there is a fault in the in‐
corporation of the evaporator for cooling the high-voltage com‐
ponents in the high-voltage system's coolant circuit, or if a
pump installed there or a valve is not OK. Although the high-
voltage battery heat exchanger is cooled, the coolant does not
reach the high-voltage components which need to be cooled
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Coolant circuit
♦ Further notes ⇒ page 245


fication
• High and low pressure nor‐ ♦ Activation of air conditioner compres‐ – Check activation and opera‐
mal at first, but after a while: sor faulty ⇒ Vehicle diagnostic tester in tion of air conditioner com‐
“Guided Fault Finding” mode pressor and perform servic‐
• High pressure rises above ing ⇒ Vehicle diagnostic
specified value ♦ One of the valves installed in the re‐ tester in “Guided Fault Find‐
frigerant circuit is defective or does not ing” mode.
• Low pressure drops to function properly ⇒ Heating, air condi‐
specified value or below tioning; Rep. gr. 87 ; Refrigerant circuit – Check operation and activa‐
• Required cooling output is (vehicle-specific Workshop Manual). tion of the various valves in‐
not attained in evaporator in ♦ Moisture in refrigerant circuit stalled in refrigerant circuit
air conditioning unit (and/or by observing pressure distri‐
in evaporator for cooling bution in refrigerant circuit
high-voltage components) ⇒ Vehicle diagnostic tester in
Or and ⇒ Heating, air condition‐
• High and low pressure nor‐ ing; Rep. gr. 87 ; Refrigerant
mal at first circuit (vehicle-specific
Workshop Manual).
• After driving for a while, low
pressure drops below – Clean refrigerant circuit
specified value (evaporator (flush with refrigerant R134a
in air conditioning unit ices ⇒ page 88 ).
up)
– Renew receiver with dryer.

– Repeat test.
Note
♦ It is not necessary at first to clean the refrigerant circuit (to flush

it with refrigerant R134a ⇒ page 88 ) when this issue occurs
as there is usually only a small quantity of moisture in the sys‐
tem which can be removed by lengthy evacuation.
♦ A faulty evaporator output temperature sender - G263- or
pressure/temperature sender can also cause the refrigerant
circuit to ice up. If this issue occurs, you should therefore also
check the measured valves of the various pressure/tempera‐
ture senders in the refrigerant circuit ⇒ Vehicle diagnostic
tester in “Guided Fault Finding” mode and ⇒ Heating, air con‐
ditioning; Rep. gr. 00 ; Repair instructions; Checking cooling
output (vehicle-specific Workshop Manual).


fication
• High pressure normal ♦ Activation of air conditioner compres‐ – Check activation and opera‐
sor faulty ⇒ Vehicle diagnostic tester in tion of air conditioner com‐
• Low pressure too low “Guided Fault Finding” mode pressor and perform servic‐
• Required cooling output is ♦ One of the valves installed in the re‐ ing ⇒ Vehicle diagnostic
not attained in evaporator in tester in “Guided Fault Find‐
frigerant circuit is defective or does not ing” mode.
air conditioning unit (and/or function properly ⇒ Heating, air condi‐
in evaporator for cooling tioning; Rep. gr. 87 ; Refrigerant circuit – Check operation and activa‐
high-voltage components) (vehicle-specific Workshop Manual). tion of the various valves in‐
♦ One of the pressure/temperature send‐ stalled in refrigerant circuit
ers in the refrigerant circuit is supplying by observing pressure distri‐
incorrect values bution in refrigerant circuit
⇒ Vehicle diagnostic tester in
Workshop Manual).

⇒ page 88 ).
♦ Shut-off valve upstream of expansion – Clean refrigerant circuit
valve for evaporator in front heater and (flush with refrigerant R134a
air conditioning unit defective ⇒ page 88 ). Not always nec‐
essary; refer to notes.
♦ Expansion valve for evaporator in front
heater and air conditioning unit defec‐ – Renew expansion valve for
tive evaporator in front heater
and air conditioning unit and
for receiver/dryer.

OK:

pressor.
– Repeat test.

Note
♦ If the fault “High pressure normal, low pressure too low” oc‐
curs, please note that the evaporator in the air conditioning
unit may ice up although the amount of refrigerant in the circuit
is OK.
♦ If the fault is caused by the air conditioner compressor (the air
conditioner compressor is activated at excessively high speed
by the control unit for air conditioning compressor - J842- ), it
is not necessary to clean the refrigerant circuit (to flush it with
refrigerant R134a ⇒ page 88 ). In this case it is sufficient to
renew the air conditioner compressor (observe quantity of re‐
frigerant oil in compressor and adjust if necessary).
♦ If the expansion valve upstream of the evaporator for cooling
the high-voltage components is defective (or its operation or
activation is faulty), permanently closed or does not open suf‐
ficiently, the air conditioner compressor is also activated to
maximum output (the required temperatures in the heat ex‐
changer are not reached). The pressure on the low-pressure
side then only drops to or below the specified value if no cool‐
ing output is requested in the front heater and air conditioning
unit at the same time. The air conditioner compressor draws
off the refrigerant from the low-pressure side of both evapo‐
rators. However, as no refrigerant can flow via the expansion
valve in the front heater and air conditioning unit, and the cool‐
ing output is not reached in the evaporator for cooling the high-
voltage components (there is a fault in the area of the
evaporator for cooling the high-voltage components), the elec‐
tric air conditioner compressor is activated at a higher speed.
However, as no more refrigerant can flow, the pressure on the
low-pressure side drops below the specified value and the
since there is no energy exchange. The same applies if a valve
in the refrigerant circuit is not OK, if there is a fault in the in‐
corporation of the evaporator for cooling the high-voltage com‐
ponents in the high-voltage system's coolant circuit, or if a
pump installed there or a valve is not OK. Although the high-
voltage battery heat exchanger is cooled, the coolant does not
reach the high-voltage components which need to be cooled
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Coolant circuit
♦ A faulty evaporator output temperature sender - G263- or
pressure/temperature sender can also cause this issue. You
should therefore also check the measured valves of the vari‐
ous pressure/temperature senders in the refrigerant circuit
Manual).


fication
• High pressure normal or too ♦ Activation of air conditioner compres‐ – Check activation and opera‐
high sor faulty ⇒ Vehicle diagnostic tester in tion of air conditioner com‐
• Low pressure too high ing ⇒ Vehicle diagnostic
♦ One of the valves installed in the re‐ tester in “Guided Fault Find‐
• Noise from air conditioner frigerant circuit is defective or does not
compressor (particularly af‐ ing” mode.
function properly ⇒ Heating, air condi‐
ter being switched on) tioning; Rep. gr. 87 ; Refrigerant circuit – Check operation and activa‐
• Required cooling output is (vehicle-specific Workshop Manual). tion of the various valves and
not attained in evaporator in ♦ One of the pressure/temperature send‐ pressure/temperature send‐
front heater and air condi‐ ers in the refrigerant circuit is supplying ers installed in refrigerant cir‐
tioning unit and/or in evap‐ incorrect values cuit by observing pressure
orator for cooling high-volt‐ distribution in refrigerant cir‐
age components cuit ⇒ Vehicle diagnostic
ing” mode and ⇒ Heating, air
conditioning; Rep. gr. 87 ;
Refrigerant circuit (vehicle-
♦ Too much refrigerant in circuit – Extract refrigerant from re‐
frigerant circuit.

– Repeat test.
• The quantity of refrigerant

extracted corresponds
ty.
below).
♦ Shut-off valve upstream of expansion – Check shut-off valve ⇒ Heat‐
valve for evaporator in front heater and ing, air conditioning; Rep. gr.
air conditioning unit defective 87 ; Refrigerant circuit (vehi‐
♦ Expansion valve for evaporator in front ual).
tive – Renew expansion valve for
♦ Air conditioner compressor defective evaporator in front heater
and air conditioning unit and
for receiver/dryer.

OK.

pressor.

Note


fication
mal sor faulty ⇒ Vehicle diagnostic tester in tion of air conditioner com‐
• Required cooling output is ing ⇒ Vehicle diagnostic
not attained in evaporator in ♦ One of the valves installed in the re‐ tester in “Guided Fault Find‐
air conditioning unit (and in frigerant circuit is defective or does not ing” mode.
evaporator for cooling high- function properly ⇒ Heating, air condi‐
voltage components) tioning; Rep. gr. 87 ; Refrigerant circuit – Check operation and activa‐
(vehicle-specific Workshop Manual). tion of the various valves and
Or
• High and low pressure nor‐ ♦ One of the pressure/temperature send‐ pressure/temperature send‐
mal ers in the refrigerant circuit is supplying ers installed in refrigerant cir‐
incorrect values cuit by observing pressure
• Noise from air conditioner distribution in refrigerant cir‐
compressor (particularly af‐ cuit ⇒ Vehicle diagnostic
ter being switched on) tester in “Guided Fault Find‐
• Required cooling output is conditioning; Rep. gr. 87 ;
not attained in evaporator in Refrigerant circuit (vehicle-
air conditioning unit (and/or specific Workshop Manual).
in evaporator for cooling
♦ Too much refrigerant in circuit – Discharge refrigerant circuit.

♦ Expansion valve for evaporator in front – Clean refrigerant circuit
heater and air conditioning unit defec‐ (flush with refrigerant R134a
tive ⇒ page 88 ).
♦ Too much refrigerant oil in circuit
– Add correct quantity of refrig‐
erant oil to circuit (refer to
note).
– Repeat test.

Note
♦ If, for example, the expansion valve for the evaporator in the
air conditioning unit or for the evaporator for cooling the high-
voltage components is defective (permanently open), the
evaporator temperature (in the front heater and air condition‐
ing unit or in the evaporator for cooling the high-voltage com‐
ponents) is no longer regulated such that the refrigerant
emerging from the evaporator outlet is in gaseous form only.
Under certain usage conditions, liquid droplets may then be
drawn in by the air conditioner compressor and result in noise
(liquid cannot be compressed).
cleaning the refrigerant circuit (flushing with refrigerant R134a

fication
mal sor faulty ⇒ Vehicle diagnostic tester in tion of air conditioner com‐
• Required cooling output is ing ⇒ Vehicle diagnostic
not attained in evaporator at ♦ One of the valves installed in the re‐ tester in “Guided Fault Find‐
front heater and air condi‐ frigerant circuit is defective or does not ing” mode.
tioning unit (and at evapo‐ function properly ⇒ Heating, air condi‐
rator for cooling high-volt‐ tioning; Rep. gr. 87 ; Refrigerant circuit – Check operation and activa‐
age components) (vehicle-specific Workshop Manual). tion of the various valves and
• Required cooling output is ♦ One of the pressure/temperature send‐ pressure/temperature send‐
not attained at evaporator ers in the refrigerant circuit is supplying ers installed in refrigerant cir‐
for heat pump operation incorrect values cuit by observing pressure
distribution in refrigerant cir‐
cuit ⇒ Vehicle diagnostic
conditioning; Rep. gr. 87 ;
Refrigerant circuit (vehicle-
One of the pumps or valves in the high- – Check operation and activa‐
voltage system's coolant circuit or the en‐ tion of components for cool‐
gine coolant circuit is defective or does not ing high-voltage compo‐
function properly ⇒ Heating, air condition‐ nents ⇒ Vehicle diagnostic
ing; Rep. gr. 87 ; Coolant circuit (vehicle- tester in “Guided Fault Find‐
specific Workshop Manual). ing” mode for air conditioner,
air conditioner compressor
and battery regulation.
– Check incorporation of heat

exchanger into engine cool‐
ant circuit and function and
activation of the various
pumps and valves ⇒ Heat‐
ing, air conditioning; Rep. gr.
87 ; Coolant circuit .

Note
♦ If the required cooling output of the evaporator in the front

heater and air conditioning unit (and the evaporator for cooling
the high-voltage components) is OK and there is a problem
due to a lack of heating output at the heat exchanger for heat
pump operation. The cause may lie in the coolant circuit of the
high-voltage system or the engine coolant circuit. If the pumps
and valves in the high-voltage system's coolant circuit are not
activated correctly or if their operation is not OK, not enough
heat energy can be absorbed from the coolant via the evapo‐
rator (heat exchanger) for the high-voltage system compo‐
nents. If the pumps and valves in the engine coolant circuit are
not activated correctly or if their operation is not OK, the ab‐
sorbed heat energy cannot be transferred via the heat ex‐
changer for heat pump function to the coolant flowing to the
heat exchanger in the heater and air conditioning unit ⇒ Ve‐
Heating, air conditioning; Rep. gr. 87 ; Coolant circuit (vehicle-

9 Renewing components of refrigerant

circuit
⇒ “9.1 Renewing components”, page 258
9.1 Renewing components
WARNING

discharged.
• All components of the refrigerant circuit submitted for quality

analysis must always be sealed (use original sealing caps of
replacement part).
• To date, the replacement parts "air conditioner compressor,
reservoir, receiver, evaporator and condenser" have been fil‐
led with nitrogen gas. This filling is being gradually discontin‐
ued/the pressure of the nitrogen filling is now so low that it is
no longer possible to perceive gas escaping upon initial open‐
ing.
• On vehicles fitted with an air conditioner compressor without
a magnetic clutch, the engine should only be started following
the complete assembly of the refrigerant circuit (with com‐
pressor always in operation).
• When the refrigerant circuit is empty, the air conditioner com‐
pressor with air conditioner compressor regulating valve -
N280- (no magnetic clutch) is switched to internal lubrication
with the result that only a minimal amount of oil is pumped from
the air conditioner compressor into the circuit.

Note
♦ As parts are sometimes stored for lengthy periods and at dif‐

ferent locations within the spare parts organisation, it is en‐
tirely possible that gas will escape from some parts and not
from others on initial opening (even in the case of identical
spare part numbers). Sealing caps at replacement part con‐
nections must therefore be detached carefully and the nitro‐
gen gas allowed to escape slowly.
♦ Refrigerant circuits are fitted either with a restrictor and reser‐
voir or with an expansion valve and receiver.
♦ Always renew desiccant cartridge or components with desic‐
cant bag (reservoir, receiver) after cleaning refrigerant circuit
(flushing with refrigerant R134a ⇒ page 88 or blowing out with
compressed air and nitrogen ⇒ page 84 ); when doing so,
leave sealed as long as possible to minimise the absorption of
moisture.
♦ Renew desiccant cartridge or components with desiccant bag
(reservoir, receiver) if required for certain repair operations or
if the refrigerant circuit has been open for a relatively long pe‐
riod and moisture has entered (e.g. following an accident)
⇒ page 260 .
♦ The period of time for which a refrigerant circuit may be left
open without having to renew a component with desiccant bag
(reservoir, receiver) depends strongly on ambient influences.
At high ambient temperatures and high humidity levels, or if
the vehicle has been standing e.g. in the open or driven (in
wet, foggy weather conditions), this period of time will be con‐
siderably shorter than for a vehicle which has been standing
in a heated, dry area. The size of the opening through which
moisture may enter into the circuit also influences the period
for which a refrigerant circuit can be left open without having
to renew components with desiccant bag ⇒ page 260 .
♦ Seal open connections and lines (to prevent absorption of
moisture).
♦ Always renew restrictor.
Caution
♦ Contaminated refrigerant oils must be disposed of as used

oils of unknown origin (observe local regulations) ⇒ Audi
ServiceNet, HSO Environmental Protection .
9. Renewing components of refrigerant circuit 259

⇒ “9.1.1 Leaking or damaged components (except air conditioner

compressor, reservoir or receiver)”, page 260
⇒ “9.1.2 Leaking or damaged components (except air conditioner
compressor, reservoir or receiver)”, page 262
⇒ “9.1.3 Renewing air conditioner compressor without having to
clean refrigerant circuit”, page 262
⇒ “9.1.4 Renewing air conditioner compressor due to leakage or
internal damage”, page 265
⇒ “9.1.5 Renewing receiver or reservoir and restrictor after clean‐
ing refrigerant circuit”, page 266
⇒ “9.1.6 Renewing receiver or reservoir without having to clean
refrigerant circuit”, page 268
⇒ “9.1.7 Renewing desiccant cartridge/desiccant bag without
having to clean refrigerant circuit”, page 269
⇒ “9.1.8 Removing/installing and renewing air conditioner com‐
pressor regulating valve N280 ”, page 269
9.1.1 Leaking or damaged components (ex‐

cept air conditioner compressor, reser‐
voir or receiver)
Refrigerant circuit completely empty (e.g. in the event of major
leakage or a burst hose)
Note
♦ In the event of only a minor leak with slow escape of refrigerant

(e.g. at a small leakage point), the amount of refrigerant oil lost
and the amount of moisture ingressing is not sufficient to in‐
fluence operation of the air conditioner.
♦ The work marked * must only be performed if there is a major
leak (e.g. following an accident).

– Remove faulty component ⇒ Heating, air conditioning; Rep.
ual).
– Remove and flush the electrically driven air conditioner com‐
pressor ⇒ page 106 *.
– Clean the refrigerant circuit (flush with refrigerant R134a)
⇒ page 88 *.
– Pour the full specified quantity of refrigerant oil into the air
conditioner compressor or circuit *.
– Remove faulty component ⇒ Heating, air conditioning; Rep.
ual).
– Removing the air conditioner compressor ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Air conditioner compressor (vehicle-
specific Workshop Manual)*.

– Remove oil drain plug -B-/-D- from air conditioner compressor

-A-.*
Note
♦ The design of the oil drain plug -B- / -D- and the seal -C- /
-E- varies (depending on the air conditioner compressor man‐
ufacturer).
♦ Observe the correct tightening torque when fitting the oil drain
plug -B- / -D- (depends on the air conditioner compressor
manufacturer and the design of the oil drain plug). For exam‐
ple, on air conditioner compressors manufactured by Denso
or Delphi, a seal is fitted at the oil drain plug (tightening torque:
currently 30 Nm for Denso, and 15 Nm for Delphi). On air con‐
ditioner compressors manufactured by Sanden or Zexel/Va‐
leo, an O-ring or a seal is fitted at the oil drain plug depending
on the version (tightening torque: currently 10 Nm for O-ring
and seal).
♦ On Denso/Nippondenso or Delphi air conditioner compres‐
sors, for example, a seal -E- is fitted at the oil drain plug -D-;
renewing seal ⇒ Electronic parts catalogue .
♦ On air conditioner compressors manufactured by Sanden or
Zexel/Valeo, an O-ring or a seal -C- is fitted at the oil drain plug
-B-, depending on the version; renewing O-ring/seal ⇒ Elec‐
♦ If the seal/O-ring fitted at the oil drain plug cannot be supplied
as a replacement part, the removed component can be re-in‐
stalled as an exception; it must be checked for damage before
being re-installed. If the removed seal/O-ring is damaged or
deformed, it must be replaced by a commercially available
component.
♦ To accelerate discharging of refrigerant oil, rotate air condi‐
tioner compressor e.g. via clutch plate of magnetic clutch.
♦ After charging the refrigerant circuit, check the installed oil
drain plug for leaks, e.g. with an electronic leak detector.
♦ Pour the old refrigerant oil out of the air conditioner compres‐
sor (disposal ⇒ Audi ServiceNet, HSO Environmental Protec‐
tion ).
All vehicles:
Note
♦ Then fill the air conditioner compressor with the quantity of

fresh refrigerant oil corresponding to the quantity of refrigerant
oil in the replacement compressor ⇒ page 317 *.
♦ Use different refrigerant oils and quantities for the various air
conditioner compressors ⇒ page 317 .
♦ To ensure air conditioner compressor lubrication on start-up,
at least 40 cm3 of refrigerant oil must be poured into the air
conditioner compressor. The remainder can be added for ex‐
ample to the new reservoir or receiver ⇒ page 317 .
♦ If dirt has entered into the air conditioner compressor with the
refrigerant circuit open (e.g. after an accident), renew the air
conditioner compressor.
♦ Clean refrigerant circuit (flush with refrigerant R134a
⇒ page 88 or blow out with compressed air or nitrogen
⇒ page 84 )*.

– Renew desiccant cartridge*, receiver* or reservoir* and re‐

strictor ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
– Assemble, evacuate and re-charge refrigerant circuit.
9.1.2 Leaking or damaged components (ex‐

cept air conditioner compressor, reser‐
voir or receiver)
Refrigerant circuit still contains refrigerant (e.g. in the event of a
minor leak)
– Remove defective component, flush with compressed air and
collect escaping refrigerant oil.
– Charge new component with amount of refrigerant oil blown
out (plus 20 cm3 for evaporator, plus 10 cm3 for condenser,
refrigerant lines and refrigerant hoses) as fresh refrigerant oil
fill.
Note
Disposal of old refrigerant oil ⇒ Audi ServiceNet, HSO Environ‐

mental Protection .
– Renew restrictor ⇒ Heating, air conditioning; Rep. gr. 87 ;

– Assemble, evacuate and charge refrigerant circuit.
9.1.3 Renewing air conditioner compressor

without having to clean refrigerant circuit
Note
♦ Cleaning the refrigerant circuit means flushing it with refriger‐

ant R134a ⇒ page 88 .
For example in the event of exterior damage after an accident (or

in the event of an electrical fault)
Workshop Manual).
Note
Use different refrigerant oils and quantities for the various air con‐
ditioner compressors
⇒ “10.2.2 Refrigerant oil capacities”, page 321 .


♦ If an electrically driven air conditioner compressor is renewed,
the quantity of refrigerant oil in the removed air conditioner
compressor must be determined by flushing
( ⇒ “5.5.2 Flushing electrically driven air conditioner compres‐
sor (removing refrigerant oil)”, page 106 ) the air conditioner
compressor. You must then pour enough refrigerant oil out of
the new air conditioner compressor so that the quantity of re‐
frigerant oil remaining in the compressor is the same as the
quantity flushed from the removed compressor
( ⇒ “10.2.2 Refrigerant oil capacities”, page 321 ).
Example:
♦ 120 cm3 was flushed out of the air conditioner compressor to
be renewed
(removing refrigerant oil)”, page 106 .
♦ The air conditioner compressor to be installed contains 200
cm3 of refrigerant oil (see rating plate and
⇒ “10.2.2 Refrigerant oil capacities”, page 321 ).
– Pour refrigerant oil out of the new air conditioner compressor
(first using the connection for the refrigerant line on the low-
pressure side) until the quantity of refrigerant oil remaining is
the same as the quantity previously flushed out of the air con‐
ditioner compressor to be renewed (plus 10 cm3). In the ex‐
ample, this is 110 cm3 of refrigerant oil (this ensures that the
refrigerant circuit contains the correct quantity of refrigerant oil
after the new air conditioner compressor is installed).

Note
♦ With the electrically driven air conditioner compressor, the re‐

frigerant oil cannot be poured out in the same way and to the
same extent as with the mechanically driven air conditioner
compressor. There is no oil drain plug, the air conditioner
compressor cannot be turned and the internal structure means
that, depending on the version of the air conditioner compres‐
sor and how it was stored, only a small amount of the refrig‐
erant oil can be poured out (due to differences in how the
refrigerant oil is distributed in the air conditioner compressor).
A residual quantity of between 30 and 80 cm3 will usually re‐
main in the air conditioner compressor after the pouring oper‐
ation. Depending on the problem, the removed air conditioner
compressor must therefore be flushed in order to remove the
refrigerant oil and determine the quantity contained
♦ If the required quantity of refrigerant oil cannot be poured out
of the air conditioner compressor to be newly installed, then
the new air conditioner compressor must also be flushed. The
new air conditioner compressor must then be filled up with the
same quantity of new refrigerant oil as was previously flushed
out of the old air conditioner compressor
♦ The refrigerant oil has roughly the same density as water at
room temperature (1 kg corresponds to one litre).
♦ Even electric air conditioner compressors of the same con‐
struction (same manufacturer, same part number) do not
weigh the same, which means that the quantity of refrigerant
oil they contain cannot be determined by weighing them (the
tolerances are too large to determine the quantity of refrigerant
oil by weighing).
♦ The distribution of the refrigerant oil in the air conditioner com‐
pressor differs depending on the structure and how the air
conditioner compressor is stored. There can be some in the
compression chamber and some in the area of the electric
motor, in which case the refrigerant oil must be alternately
poured out via the two connections for the refrigerant pipes
(high and low-pressure side). The air conditioner compressor
must be positioned so that the respective connection is as low
as possible.
♦ Dispose of refrigerant oil which is no longer required after
flushing out of the defective air conditioner compressor and
pouring out of the new air conditioner compressor ⇒ Audi
ServiceNet, HSO Environmental Protection (observe local
regulations).

– Remove the oil drain plug from the air conditioner compressor
(mechanically driven air conditioner compressor).
Note
There are different versions of the oil drain plug and the corre‐
sponding seal (an O-ring or a seal may be fitted, always renew)
⇒ page 260 and ⇒ Electronic parts catalogue .
– To accelerate discharging of refrigerant oil, rotate air condi‐


– Pour the old refrigerant oil out of the air conditioner compres‐
sor and dispose of it ⇒ Audi ServiceNet, HSO Environmental
Protection (observe local regulations).
– Remove the oil drain plug from the replacement compressor,
pour out the refrigerant oil into a clean vessel and only add a
quantity of fresh refrigerant oil equal to the amount poured out
of the defective air conditioner compressor.
Caution
Risk of damage to the air conditioner compressor due to con‐

taminated refrigerant oil
♦ Refrigerant oil that has been poured out of a new air con‐
ditioner compressor may only be re-used if it is in a clean
vessel and the required quantity is added back into the air
conditioner compressor immediately after pouring.
♦ Do not re-use refrigerant oil into which dirt or moisture has
gotten; it must be disposed of.
Note
♦ If, for example, 70 cm3 of refrigerant oil has been poured out
of the defective air conditioner compressor and 220 cm3 out
of the replacement compressor (a small quantity of refrigerant
oil remains in the air conditioner compressor), In this case, fill
up the air conditioner compressor to be installed with 70 cm3
of refrigerant oil. The refrigerant oil poured out of the new (re‐
placement) air conditioner compressor may be used if there is
no dirt or moisture in it).
♦ If a greater quantity of refrigerant oil (more than approx. 40
cm3) has been poured out of the defective air conditioner com‐
pressor, the remaining refrigerant oil can also be added to the
evaporator or reservoir/receiver ⇒ page 276 .
All vehicles:
– Renew restrictor (only if installed in this refrigerant circuit).
9.1.4 Renewing air conditioner compressor

due to leakage or internal damage
For example due to noise from the air conditioner compressor or
no air conditioner compressor output

Note
♦ The refrigerant circuit does not always need to be cleaned in

the event of damage to the electrical components of the air
conditioner compressor, for example the air conditioner com‐
pressor regulating valve - N280- of the mechanically driven air
conditioner compressor or the air conditioner compressor con‐
trol unit - J842- of the electrically driven air conditioner com‐
pressor. In this case it is usually sufficient to renew the air
conditioner compressor without cleaning the refrigerant circuit
(adjust the quantity of refrigerant oil)

Workshop Manual).
– Clean refrigerant circuit (flush with refrigerant R134a)
⇒ page 88 .
Note
♦ In the event of internal (air conditioner compressor) damage,

check refrigerant hoses and condenser. If e.g. swarf has en‐
tered, clean refrigerant hoses and condenser (flush with re‐
frigerant R134a ⇒ page 88 ) and renew refrigerant hoses if
necessary.
♦ On vehicles with two evaporators, the quantity of refrigerant
oil in the refrigerant circuit may be greater than the quantity in
the replacement compressor. On such vehicles, add the extra
quantity of refrigerant oil to the refrigerant circuit as necessary
⇒ page 84 .
– Renew desiccant cartridge, receiver or reservoir and restrictor

– Check expansion valve for dirt and corrosion, and renew if
necessary ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
9.1.5 Renewing receiver or reservoir and re‐

strictor after cleaning refrigerant circuit
Note
Cleaning refrigerant circuit means flushing with refrigerant R134a

⇒ page 88 or blowing out with compressed air or nitrogen
⇒ page 84 .

Due to moisture entering (refrigerant circuit open for lengthy pe‐

riod) or contamination (example)
Workshop Manual).
– Eliminate cause of fault.
– Clean refrigerant circuit (flush with refrigerant R134a)
⇒ page 88 .
– Check expansion valve for dirt or corrosion and renew if nec‐
essary
– Flush old refrigerant oil out of air conditioner compressor
– Remove oil drain plug from air conditioner compressor.
Note
There are different versions of the oil drain plug and the corre‐
sponding seal (an O-ring or a seal may be fitted; renew)
⇒ page 260 and ⇒ Electronic parts catalogue .
– To accelerate discharging of refrigerant oil, rotate air condi‐

– Pour old refrigerant oil out of air conditioner compressor.
Note
Dispose of old refrigerant oil ⇒ Audi ServiceNet, HSO Environ‐

mental Protection (observe local regulations).
All air conditioner compressors

– Then add the quantity of fresh refrigerant oil to the air condi‐
tioner compressor corresponding to the quantity of refrigerant
oil in the replacement compressor (or the specified quantity of
refrigerant oil on vehicles with two evaporators if applicable)
⇒ page 317 .

Note
♦ To ensure air conditioner compressor lubrication on start-up,
at least 40 cm3 of refrigerant oil must be poured into the air
conditioner compressor. The remainder can be added for ex‐
ample to the new reservoir or receiver ⇒ page 276 .
♦ If dirt has entered into the air conditioner compressor with the
refrigerant circuit open (e.g. after an accident), renew the air
conditioner compressor.
♦ On vehicles with two evaporators, the quantity of refrigerant
oil in the refrigerant circuit may be greater than the quantity in
the replacement compressor. On such vehicles, add the extra
quantity of refrigerant oil to the refrigerant circuit as necessary
⇒ page 84 .
All vehicles
– Renew receiver or reservoir and restrictor ⇒ Heating, air con‐
Workshop Manual).
9.1.6 Renewing receiver or reservoir without

having to clean refrigerant circuit
Note

⇒ page 84 .
For example in the event of accident damage; no refrigerant es‐

caped and no ingress of moisture and dirt into the circuit.
– Renew restrictor ⇒ Heating, air conditioning; Rep. gr. 87 ;
– Remove receiver or reservoir ⇒ Heating, air conditioning;
Manual).
– Remove dirt from receiver or reservoir.
– Weigh receiver or reservoir removed.
– Fill the new receiver or reservoir with refrigerant oil until it at‐
tains the weight of the vessel removed.
– Install new receiver or reservoir.

9.1.7 Renewing desiccant cartridge/desiccant

bag without having to clean refrigerant
circuit
Note

⇒ page 84 .
In the event of a leak, refrigerant has escaped but no dirt has

entered the circuit (example)
– Renew desiccant cartridge ⇒ Heating, air conditioning; Rep.
ual).
9.1.8 Removing/installing and renewing air

conditioner compressor regulating valve
- N280-

Note
♦ Certain malfunctions of -N280- (e.g. sticking valve or open cir‐

cuit in coil) can lead to problems with air conditioner compres‐
sor (no cooling output from air conditioner, evaporator icing up
etc.). If -N280- is the cause (and not the actual air conditioner
compressor), the air conditioner compressor can be repaired
by renewing -N280- -C, D-.
♦ -N280- -C, D- is not available as a replacement part for all air
conditioner compressors. If -N280- cannot be obtained sepa‐
rately for a particular air conditioner compressor, the entire air
conditioner compressor must be renewed ⇒ Electronic parts
catalogue .
♦ -N280- is available in different versions and with different set‐
tings ⇒ Electronic parts catalogue . On the air conditioner
compressor -A- (in this case a “Denso” air conditioner com‐
pressor without air conditioning system magnetic clutch -
N25- ), the connector for connection to the vehicle wiring
harness is attached to -N280- -C- via a short wiring harness.
On the air conditioner compressor -B- (in this case a “Sanden”
air conditioner compressor), the connector for connection to
the vehicle wiring harness is attached directly to -N280- -C-.
The procedures for removing and installing versions
-C and D - of -N280- for other air conditioner compressors
(different version, different manufacturer) are essentially the
same and usually only differ slightly from the procedure de‐
scribed below.
♦ -N280- is available in different versions and with different set‐
tings ⇒ Electronic parts catalogue . On air conditioner com‐
pressors with -N25- (in this case a “Denso” air conditioner
compressor), the connector for connection to the vehicle wir‐
ing harness is attached directly to -N280- -A-. On the other air
conditioner compressor, the connector for connection to the
vehicle wiring harness is incorporated into a 3-pin connector
-E- for -N25- and -N280- .
♦ On version -B- of -N280- , the wiring may be connected directly
to -N280- or there may be an additional connector at -N280- .
♦ The procedure for removing and installing versions
-A and B- of -N280- is essentially the same and usually only
differs slightly from the procedure described below. On air
conditioner compressors with a 3-pin connector -E-, discon‐
nect the wires to -N280- from -N280- , unplug them from the
connector -E- or sever them at a suitable location (and re-
connect them using wiring connectors from wiring harness
repair set - VAS 1978 B- .
♦ If, after removing -N280- , the cause of the problem at -N280-
is found to be dirt, swarf or some other form of air conditioner
compressor abrasion, clean the refrigerant circuit and renew
the air conditioner compressor
⇒ “9.1.4 Renewing air conditioner compressor due to leakage
or internal damage”, page 265 and
R134a”, page 88
Removing
– Discharging refrigerant circuit
page 69

Caution
Risk of air conditioner compressor damage if the refrigerant

circuit is empty
Never start the engine when the refrigerant circuit is empty.
♦ Depending on the version of the air conditioner service
station, the pressure in the refrigerant circuit may be less
than 1 bar absolute following drainage.
♦ Depending on the version, the air conditioner compressor
may be damaged by running it when the pressure in the
refrigerant circuit is low.
♦ Never start the engine if the pressure in the refrigerant
circuit is below ambient pressure.
– Depending on vehicle and fitting location of air conditioner

compressor, remove components impeding access to -N280-
Vehicles where it is not possible to detach or remove at least one
of the two refrigerant lines and -N280- with the air conditioner
compressor attached to the engine
Workshop Manual).
Note
With the air conditioner compressor in position, a refrigerant line

has to be detached to ensure that the pressure in the air condi‐
tioner compressor is the same as the ambient pressure.
Vehicles where it is possible to detach or remove at least one of

the two refrigerant lines and -N280- with the air conditioner com‐
pressor attached to the engine (air conditioner compressor is not
removed)
WARNING

♦ Before removing -N280- , connect the air conditioner serv‐
ice station and extract refrigerant. The refrigerant circuit
must be empty; danger of injury.
♦ Refrigerant and refrigerant oil will emerge if the refrigerant
circuit has not been drained.
♦ The refrigerant is to be extracted before removing -N280- .
Renewed evaporation may create pressure in the refrig‐
erant circuit if -N280- is not removed within 10 minutes
following extraction. Extract refrigerant again.
– Check the pressure in the refrigerant circuit again by way of

the pressure gauge of the air conditioner service station.
♦ If the pressure displayed is higher than the ambient pressure
(greater than approx. 1 bar absolute), switch the air condition‐
er service station on again and extract the refrigerant causing
the pressure build-up.

– Detach one of the two refrigerant lines from air conditioner

compressor ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
Note
With the air conditioner compressor in position, a refrigerant line

has to be detached to ensure that the pressure in the air condi‐
tioner compressor is the same as the ambient pressure.
All vehicles
– Before removing -N280- , check again whether the air condi‐
tioner compressor is actually being driven by the pulley/drive
unit. If the overload protection device of the pulley or drive unit
has been tripped, the malfunction is usually not caused by the
regulating valve, but by the air conditioner compressor (e.g.
because it is stiff).
Note
♦ This illustration shows -N280- -B- for a “Sanden” air condi‐

tioner compressor of type “PXE 14”. On these air conditioner
compressors, the connector for connection to the vehicle wir‐
ing harness is attached directly to -N280- -B-. Removal and
installation of -N280- -B- for other air conditioner compressors
(different type, different make e.g. “Denso”, -N280- with a short
wiring harness to the connector for example) may differ. The
basic procedure is however the same, as described below for
the “Sanden” air conditioner compressor of type “PXE 14”.
♦ This illustration shows an -N280- -B- with an O-ring -E- (not
fitted on all versions).
♦ In the case of an -N280- -B- with no O-ring -E-, dirt may ingress
into the mounting for -N280- -C- as far as the O-ring -F-.
– If fitted, unfasten wiring connecting -N280- -B- to vehicle wiring

harness connector from air conditioner compressor.
Note
♦ On air conditioner compressors with air conditioning system

magnetic clutch - N25- on which -N25- is activated via the
same connector as -N280- -B-, eject the corresponding wires
from the connector (e.g. with an ejector from the wiring har‐
ness repair set - VAS 1978 B- ) ⇒ Heating, air conditioning;
Manual).
♦ If an air conditioner compressor with air conditioning system
magnetic clutch - N25- has a connector from which the elec‐
trical wires cannot be ejected, sever the wires to -N280- (or to
-N25- ) at a suitable location and re-connect using wiring con‐
nectors from the wiring harness repair set - VAS 1978 B- (or
renew the connector; refer to ⇒ Electronic parts catalogue )
⇒ Electrical system; Rep. gr. 97 ; Connectors; Repairing
electrical wiring harnesses and electrical connectors .

– Thoroughly clean the air conditioner compressor in the area

of the circlip -A- and -N280- -B-.
Caution
The pressure in the air conditioner compressor must be the

same as the ambient pressure.
♦ Refrigerant and refrigerant oil may emerge in the event of
higher pressure in the air conditioner compressor.
♦ Dirt may be drawn into the air conditioner compressor in
the event of lower pressure in the air conditioner com‐
pressor.
♦ Ensure pressure equalisation before removing -N280-
-B-.
– Remove circlip -A-.

– Carefully remove -N280- -B- from the mounting on the air con‐
ditioner compressor -C- using a suitable screwdriver -D- for
example.

– After removal, check -N280- -B- and mounting on air condi‐

tioner compressor -C- for dirt.
Note
♦ If the strainer -D-, -N280- -B- as far as the O-ring -F- or the
mounting on the air conditioner compressor -C- is severely
contaminated in this area (e g. with swarf or dark, tacky abra‐
sion), this is an indication of air conditioner compressor dam‐
age. In this case, clean the refrigerant circuit and renew air
conditioner compressor
⇒ “9.1.4 Renewing air conditioner compressor due to leakage
or internal damage”, page 265 and
R134a”, page 88
♦ If the strainer -D- at -N280- -B- and the mounting on the air
conditioner compressor -C- as far as the sealing surface of the
O-ring -F- are only slightly contaminated (e g. with light grey
deposits from normal air conditioner compressor operation),
the cause of air conditioner compressor malfunctioning may
be a problem with -N280- -B-.
♦ If -N280- -B- does not have an O-ring -E-, dirt may have en‐
tered the mounting -C- as far as the O-ring -E- during opera‐
tion. Carefully remove all dirt using a lint-free cloth or similar
(do not use compressed air).
Installing
– Check the mounting on the air conditioner compressor -C- and
the groove for the circlip for contamination and clean carefully
and thoroughly with a fresh lint-free cloth if necessary.
Caution
Dirt in the air conditioner compressor or damage to the sealing

surfaces in the mounting could lead to renewed failure of -
N280- -B- or the air conditioner compressor
♦ If necessary, carefully clean the mounting on the air con‐
ditioner compressor -C- with a fresh lint-free cloth (do not
use compressed air).
♦ When cleaning the mounting -C-, make sure no dirt in‐
gresses into the area beneath the sealing surface for the
O-ring -F- or into the ducts provided and that none of the
sealing surfaces of the mounting are damaged.
– Check air conditioner compressor mounting -C- for damage

(also check for small scratches on surface; renew air condi‐
tioner compressor if damage is found).
– Check the O-rings -F,G,H- and -E- (if fitted) of -N280- -B- for
damage.
– Moisten the O-rings -F,G,H- and -E- (if fitted) of -N280- -B- with
a small quantity of refrigerant oil and check for proper attach‐
ment.
– Insert -N280- -B- as far as it will go in air conditioner compres‐
sor mounting -C-.
– Fit a new circlip -A- and check for correct positioning in the
groove.
– Re-install all parts removed in reverse order.

– Evacuate and re-charge the refrigerant circuit

page 69 .
Note
If refrigerant oil has emerged with -N280- -B- removed, use the
air conditioner service station to add this quantity of refrigerant oil
when charging the refrigerant circuit
page 69 .
– Check operation of air conditioner

⇒ “8 Checking pressures”, page 183 and ⇒ Heating, air con‐
Workshop Manual).

10 Capacities for refrigerant R134a/re‐

frigerant oil and approved refrigerant
oils
⇒ “10.1 Capacities for refrigerant R134a”, page 276
⇒ “10.2 Approved refrigerant oils and refrigerant oil capacities”,
page 317
10.1 Capacities for refrigerant R134a

• On vehicles from Audi A8 (4N) 2018 onwards, the capacity for
refrigerant R134a can be found in the vehicle-specific Work‐
shop Manual ⇒ Heating, air conditioning; Rep. gr. 00 ;
Technical data .
Note
♦ When charging the high-pressure side of refrigerant circuits,

always fill to the upper tolerance limit (some liquid refrigerant
will remain in the filler hoses).
♦ Unless otherwise stated, the capacities specified for refriger‐
ant R134a also apply to the S and RS versions of this vehicle
model.
♦ When charging the refrigerant circuit, the air conditioner serv‐
ice station must be on the same level as the vehicle in which
the refrigerant circuit is to be charged (maximum difference 50
cm). Depending on the design of the air conditioner service
station , an excessive difference in height could lead to differ‐
ences between the quantity of refrigerant displayed and that
actually poured in. The charging accuracy of the air condition‐
er service station may change.
♦ For the assignment of the air conditioner compressor (“Zexel/
Valeo”, “Sanden” or “Denso/Nippondenso”), refer to ⇒ Elec‐
tronic parts catalogue and ⇒ Heating, air conditioning; Rep.
ual).
♦ Refrigerant circuits converted from R12 to R134a are to be
filled with the quantity indicated in the Workshop Manual “Air
conditioner with refrigerant R12”. ⇒ Air conditioning system
with refrigerant R12 (this Workshop Manual is only available
in hardcopy form).
♦ ⇒ “10.1.1 Capacities for Audi A1 (8X_) 2011 ►”, page 277

♦ ⇒ “10.1.2 Capacities for Audi A2 (8Z_) 2001 ►”, page 278
♦ ⇒ “10.1.3 Capacities for Audi A3 (8L_) 1997 ► and Audi TT
(8N_) 1999 ►”, page 279
♦ ⇒ “10.1.4 Capacities for Audi A3 (8P_) 2004 ►, Audi Q3 (8U_
or 84_ for China) 2012 ►”, page 282
♦ ⇒ “10.1.5 Capacities for Audi Q2 (GA_) 2017 ►, Audi A3 (8V_
or 85_ for China) 2013 ►, Audi A3 e-tron (8V_ ) 2015 ►, Audi
RS 3 (8V_) 2016 ►”, page 283
♦ ⇒ “10.1.6 Capacities for Audi TT (8J_) 2007 ►”, page 284
♦ ⇒ “10.1.7 Capacities for Audi TT (FV_) 2015 ►”, page 285

♦ ⇒ “10.1.8 Capacities for Audi 80 (8A_/8C_), Audi Coupé (8B_),

Audi Cabriolet (8G_) ► 2002”, page 286
♦ ⇒ “10.1.9 Capacities for Audi A4 (8D_) 1995 ► ”, page 286
♦ ⇒ “10.1.10 Capacities for Audi A4 (8E_) 2001 ►, Audi A4 Cab‐
riolet (8H_) 2003 ►”, page 289
♦ ⇒ “10.1.11 Capacities for Audi A4 (8K_) 2008 ►, Audi A5
Coupé and Sportback (8T_) 2008 ►, Audi Q5 (8R_ or 83_ for
China) 2008 ►, Audi A5 Cabriolet (8F_) 2009 ►, Audi Q5 hybrid
(8R_) 2011 ►”, page 291
♦ ⇒ “10.1.12 Capacities for Audi A4 (8W_) 2016 ►, Audi A4 (86_
for China) 2017 ►, Audi A5 (F5_) 2016 ►, Audi Q5 (FY_) 2017
►, Audi Q5 (87_ for China) 2019 ►”, page 301
♦ ⇒ “10.1.13 Capacities for Audi 100/Audi A6 (4A_) ► 1998”,
page 302
♦ ⇒ “10.1.14 Capacities for Audi A6 (4B_) 1998 ► and Audi all‐
road (4B_) ► 2005”, page 303
♦ ⇒ “10.1.15 Capacities for Audi A6 (4F_) 2005 ►”, page 308
♦ ⇒ “10.1.16 Capacities for Audi A6 (4G_ or 4X_ for China ) 2011
►, Audi A7 (4G_ or 4X_ for China) 2011 ►, Audi A6 hybrid (4G_)
2012 ►, A6 e-tron (4G_) 2017 ►”, page 309
♦ ⇒ “10.1.17 Capacities for Audi V8 (4C_) ► 1994”, page 311
♦ ⇒ “10.1.18 Capacities for Audi A8 (4D_) 1994 ►”, page 312
♦ ⇒ “10.1.19 Capacities for Audi A8 (4E_) 2003 ►”, page 313
♦ ⇒ “10.1.20 Capacities for Audi A8 (4H_) 2010 ►, Audi A8 hybrid
(4H_) 2012 ►”, page 314
♦ ⇒ “10.1.21 Capacities for Audi Q7 (4L_) 2006”, page 315
♦ ⇒ “10.1.22 Capacities for Audi Q7 (4M_) 2016 ►”, page 316
♦ ⇒ “10.1.23 Capacities for Audi R8 (42_) 2008 ►, Audi R8 (4S_)
2015 ►”, page 316
10.1.1 Capacities for Audi A1 (8X_) 2011 ►

Characteristics of refrigerant circuit:
• Expansion valve
• Receiver
• “Denso”, “Sanden” (or “Delphi/Mahle”) air conditioner com‐
N280- ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
parts catalogue
Vehicle model Production period Capacity in grams Differing characteristics of this refrigerant
circuit
Audi A1 (type From 08.10 to 500 +/- 15 • Refrigerant lines bolted to installed ex‐
code 8X1 or 06.14 (gradual in‐ pansion valve (top)
8XA) troduction)
Audi A1 (type From 06.14 on‐ 475 +/- 15 • Refrigerant lines bolted to installed ex‐
code 8XF or wards (gradual in‐ pansion valve (bottom)
8XK) troduction)
10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 277
Note
♦ Various air conditioner compressors have been fitted depend‐

ing on the production period and engine (these air conditioner
compressors have no magnetic clutch).
♦ At the start of production, “Denso” air conditioner compressors
(type “6 SEU 14C”) or “Sanden” air conditioner compressors
(“7 PXE 16/14”) were fitted; see ⇒ Electronic parts catalogue
♦ Depending on the engine, “Sanden” air conditioner compres‐
sors (type “11 PXC 14”) or “Delphi” air conditioner compres‐
sors (type “6 CVC 140”) may also be fitted at a later date
(introduction not yet finalised, planned from 09.12 onwards);
see ⇒ Electronic parts catalogue and ⇒ Heating, air condi‐
shop Manual).
♦ As of 11.2012, the quantity of refrigerant oil for the “Denso” air
conditioner compressor with part number “5Q0 xxx xxx” was
increased from 80 ccm to 110 ccm. The increased quantity of
refrigerant oil applies retroactively to all vehicles with this air
conditioner compressor. On vehicles manufactured with this
air conditioner compressor up to 11.2012, check whether the
quantity of refrigerant oil has already been increased during a
previous workshop visit. If not, add 30 ccm of refrigerant oil to
the refrigerant circuit
⇒ “10.2.3 Capacities for Audi A1 (8X_) 2011 ►”, page 322 .
Then enter the refrigerant oil capacity on the label in water‐
proof ink ⇒ Heating, air conditioning; Rep. gr. 87 ; Installation
location overview - Air conditioning (vehicle-specific Work‐
shop Manual) and fill the refrigerant circuit with the quantity of
refrigerant indicated above.
♦ From 06.14 onwards, the evaporator, expansion valve and the
corresponding refrigerant lines have been modified (different
lines, attachment points etc.). In the period from 06.14 to
11.14, these air conditioners were still filled with 500 grams of
refrigerant at the factory. From 11.14 onwards, the amount of
refrigerant was reduced from 500 grams to 475 grams. Rea‐
son: In unfavourable ambient conditions (high ambient tem‐
peratures, dirt in condenser etc.), adding 500 grams of
refrigerant may lead to excessive pressures in the refrigerant
circuit on these vehicles. On vehicles built within this period,
check the refrigerant capacity indicated on the label and cor‐
rect it if necessary to 475 grams with a waterproof pen (or
renew the label) ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant capacity (vehicle-specific Workshop Manual) and
⇒ Electronic parts catalogue .
10.1.2 Capacities for Audi A2 (8Z_) 2001 ►

• Restrictor (coloured).
• Reservoir.
• “Denso” air conditioner compressor with no magnetic clutch
and with air conditioner compressor regulating valve - N280- .

Vehicle model Production period Capacity in grams Differing characteristics of

this refrigerant circuit
Audi A2 From 06.00 525 +/- 25 • Yellow-coloured restric‐
to 07.01 tor
• Condenser, no. 8Z0 260
401 (403) with index “B”
or “C”.
From 07.01 onwards 500 +/- 25 • Red-coloured restrictor

• Condenser, no. 8Z0 260
401 (403) with index “D”.
Note
♦ Replacement restrictors with different holes are available (yel‐

low-coloured 1.54 mm, red-coloured 1.42 mm).
♦ Depending on manufacturer, colour of red restrictor may tend
more towards orange.
♦ To avoid altering the cooling output of the air conditioner, re‐
strictors with the same hole diameter must always be used.
♦ A restrictor with a smaller hole (red-coloured) and a condenser
with a smaller internal volume are installed from model year
2002 onwards. The capacity has therefore been slightly modi‐
fied (condenser -70 g, smaller restrictor +50 g) ⇒ Heating, air
Workshop Manual) and ⇒ Electronic parts catalogue .
10.1.3 Capacities for Audi A3 (8L_) 1997 ► and

Audi TT (8N_) 1999 ►
• Expansion valve
• Receiver
• “Sanden” or “Zexel/Valeo” air conditioner compressor ⇒ Heat‐
specific Workshop Manual) and ⇒ Electronic parts catalogue
Capacity for Audi A3 (8L_) 1997 to 2004
Vehicle Production period Capacity in grams Differing characteristics of this refrigerant circuit
model
Audi A3 From 08.96 750 + 50 • None
Note
♦ Exclusive use was made at the start of production of “Sanden”

air conditioner compressors. From model year 1999 onwards,
“Zexel/Valeo” air conditioner compressors have also been
used ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
parts catalogue .
♦ If no replacement condenser with a flat tube width = 20 mm is
available for an Audi A3, and a condenser with a flat tube width
= 16 mm is fitted, only 650 +/- 20 g of refrigerant may be added
(instead of 750 + 50 g). In addition the capacity given on the
label must be altered accordingly (observe notes on Audi TT
⇒ page 281 ).
Audi TT (8N_) 1999 ► capacity

Vehicle Production period Capacity in grams Differing characteristics of this refrigerant circuit
model
Audi TT From 10.98 750 + 50 • Condenser with flat tube width of 20 mm
to 10.03 (and from ⇒ page 281
06.04 to 08.04
⇒ page 281 )
From 10.03 onwards 650 +/- 20 • Condenser with flat tube width of 16 mm
(except 06.04 to ⇒ page 281
08.04 ⇒ page 281 )

Note

parts catalogue .
♦ The air conditioner compressor designation “Zexel / Valeo”
was changed as of 2006 to “Valeo”.
♦ With effect from 10.03 (as of vehicle identification number
8N41015239), production of the Audi TT was switched from
the condenser with part no. “1J0 820 411 J” (with a flat tube
width of 20 mm) to the condenser with part no. “8N0 820 411
A” (with a flat tube width of 16 mm) ⇒ page 281 . In the period
between 06.04 and 08.04, a certain number of vehicles was
again fitted with condensers with a flat tube width of 20 mm.
♦ Condensers with a flat tube width = 16 mm must be filled with
approx. 120 g less refrigerant than condensers with a flat tube
width = 20 mm ⇒ Electronic parts catalogue .
♦ In the period between 10.03 (vehicles as of vehicle identifica‐
tion number 8N41015239) and 06.04, the Audi TT was fitted
at the factory with a condenser with a flat tube width of 16 mm
(part no. “8N0 820 411 A”) and the refrigerant circuit filled with
750 + 50 grams of refrigerant. These vehicles were also pro‐
vided with a sticker showing the incorrect capacity - namely
750 grams (or 700 grams in 06.04) instead of 650 grams
⇒ page 281 . Under certain ambient conditions (e.g. high am‐
bient temperatures), over-filling of the systems may result in
the air conditioner compressor being shut off on account of
excess pressure in the refrigerant circuit. Complaints may also
be received about engine performance (e.g. humming and
drumming; the engine is subjected to greater load as the air
conditioner compressor constantly has to cope with exces‐
sively high pressure). Remedy: Discharge the refrigerant cir‐
cuit, then re-charge with the correct quantity and replace the
label with a label indicating the correct capacity or delete the
old capacity indicated on the label and enter the new capacity
in waterproof ink for example.
♦ Pay attention to flat tube dimensions if condenser is renewed.
If a condenser with different flat tube dimensions is to be fitted,
also replace the label indicating the refrigerant R134a capacity
or delete the old capacity and enter the new capacity in wa‐
terproof ink for example ⇒ Electronic parts catalogue .
Reading flat tube dimensions of condenser

♦ Flat tubes of condenser -A-
♦ Width of flat tubes -B-
Label indicating refrigerant R134a capacity
Pay attention to flat tube dimensions if condenser is renewed. If

a condenser with different dimensions is to be fitted, also replace
the label -A- indicating the refrigerant R134a capacity or delete
the old capacity and enter the new capacity in waterproof ink for
example ⇒ Electronic parts catalogue .
10.1.4 Capacities for Audi A3 (8P_) 2004 ►,

Audi Q3 (8U_ or 84_ for China) 2012 ►
Note
♦ The refrigerant capacities in the following table apply to the

Audi A3, Audi A3 Sportback, Audi RS 3, Audi A3 Cabriolet and
Audi Q3 (and RS Q3).
♦ On certain versions for China the type designation 84_ is used
instead of 8U_.

• Expansion valve
• Receiver
• “Denso”, “Delphi/Mahle”, “Sanden” or “Zexel/Valeo” air condi‐
tioner compressor with air conditioner compressor regulating
valve - N280- ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐
frigerant circuit (vehicle-specific Workshop Manual) and ⇒
Electronic parts catalogue
circuit
Audi A3 From 05.03 on‐ 525 +/- 25 • None
• With 4 or wards
6-cyl. en‐
gine
Audi RS 3 From 01.11 on‐ 500 +/- 25 • Different type of condenser fitted ⇒
• With 5-cyl. wards Electronic parts catalogue and ⇒ Heat‐
engine ing, air conditioning; Rep. gr. 87 ; Re‐
frigerant circuit (vehicle-specific Work‐
shop Manual).
Audi Q3 (and From 07.11 on‐ 520 +/- 20 • None

RS Q3) wards

Note

♦ At the start of production exclusive use was made of type “7
SEU 16” air conditioner compressors from “Denso”. From
model year 2004 onwards, a different “Denso” compressor
(type “7 SEU 17”) has gradually been replacing the old one.
♦ From model year 2004 onwards, “Zexel/Valeo” (type
“DSC17E”) and “Sanden” (type “PXE16”) air conditioner com‐
pressors are gradually being introduced, depending on the
engine ⇒ Electronic parts catalogue and ⇒ Heating, air con‐
Workshop Manual).
♦ From model year 2008 onwards, “Denso” compressors (type
“6 SEU 14”) and “Delphi/Mahle” air conditioner compressors
are also gradually being introduced depending on the engine
⇒ Electronic parts catalogue and ⇒ Heating, air conditioning;
Manual).
10.1.5 Capacities for Audi Q2 (GA_) 2017 ►,

Audi A3 (8V_ or 85_ for China) 2013 ►,
Audi A3 e-tron (8V_ ) 2015 ►, Audi RS 3
(8V_) 2016 ►
Note
The capacity for the Audi A3 (8V_ or 85_ for China) applies to all
versions (saloon, Sportback, cabriolet, etc.)

• Expansion valve
• Receiver
• Mechanically driven “Denso” or “Sanden” air conditioner com‐
parts catalogue (all vehicles except A3 e-tron)
• On vehicles with high-voltage system (A3 e-tron): electrically
driven “Sanden” or “Visteon” air conditioner compressors ⇒
hicle-specific Workshop Manual) and ⇒ Electronic parts cata‐
logue
circuit
Audi Q2 From 07.16 on‐ 500 +/- 15 • None
wards
circuit
Audi A3 From 05.12 on‐ 500 +/- 15 • None
wards
A3 e-tron From 09.14 on‐ 500 +/- 15 • Electrically driven air conditioner com‐
wards pressor
• With second evaporator in heat ex‐
changer for high-voltage battery ("chill‐
er")
Audi RS 3 From 02.15 on‐ 570 +/- 15 • Different type of condenser fitted ⇒
shop Manual).
Note
♦ Various air conditioner compressors are fitted depending on

the production period and the engine (these compressors do
not have a magnetic clutch) ⇒ Heating, air conditioning; Rep.
ual).
conditioner compressor is being increased from 80 ccm to 110
ccm. The increased quantity of refrigerant oil applies retroac‐
tively to all vehicles with this make of air conditioner compres‐
sor. On vehicles manufactured up to 11.2012, check whether
the quantity of refrigerant oil has already been increased dur‐
ing a previous workshop visit. If not, add 30 ccm of refrigerant
oil to the refrigerant circuit
⇒ “10.2.7 Capacities for Audi Q2 (GA_) 2017 ►, Audi A3 (8V_
RS 3 (8V_) 2016 ►”, page 328 . Then enter the refrigerant oil
capacity on the label in waterproof ink ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Installation location overview - Air con‐
ditioning (vehicle-specific Workshop Manual) and fill the
refrigerant circuit with the quantity of refrigerant indicated
above.
10.1.6 Capacities for Audi TT (8J_) 2007 ►

• Expansion valve
• Receiver
• “Denso”, “Delphi/Mahle” or “Sanden” air conditioner compres‐
sor with air conditioner compressor regulating valve - N280-
catalogue
circuit
Audi TT From 08.06 on‐ 525 +/- 25 • None
• With 4 or wards
6-cyl. en‐
gine

circuit
Audi TT From 03.09 on‐ 500 +/- 25 • Different type of condenser fitted ⇒
shop Manual).
Note
♦ At the start of production, exclusive use was made of air con‐

ditioner compressors of type “6 SEU 14” manufactured by
“Denso”. This air conditioner compressor has no magnetic
clutch (it is constantly driven by the engine). Air conditioner
compressors produced by other manufacturers may also be
fitted at a later date (depending on the engine) ⇒ Electronic
parts catalogue and ⇒ Heating, air conditioning; Rep. gr. 87 ;
♦ From model year 2008 onwards, “Sanden” air conditioner
compressors (type “PXE16”) are gradually being introduced
for certain engines; these air conditioner compressors do not
have a magnetic clutch (they are driven continuously by the
engine) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
♦ From model year 2011 onwards, “Delphi” air conditioner com‐
pressors are also gradually being introduced depending on the
engine ⇒ Electronic parts catalogue and ⇒ Heating, air con‐
Workshop Manual).
10.1.7 Capacities for Audi TT (FV_) 2015 ►

• Expansion valve
• Receiver
parts catalogue
circuit
Audi TT From 10.14 on‐ 500 +/- 15 • None
wards
Audi TT RS From 07.16 on‐ 570 +/- 15 • Different type of air conditioner com‐
• With 5-cyl. wards pressor and condenser fitted ⇒ Elec‐
engine tronic parts catalogue and ⇒ Heating,
air conditioning; Rep. gr. 87 ; Refriger‐
ant circuit (vehicle-specific Workshop
Manual).
Note
Various air conditioner compressors are fitted depending on the

production period and the engine (these compressors do not have
a magnetic clutch) ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐
frigerant circuit (vehicle-specific Workshop Manual).
10.1.8 Capacities for Audi 80 (8A_/8C_), Audi Coupé (8B_), Audi Cabriolet (8G_)
► 2002
• Restrictor (not coloured).
• Reservoir
• “Zexel/Valeo” air conditioner compressor ⇒ Heating, air con‐
Workshop Manual) and ⇒ Electronic parts catalogue
Vehicle model Production period Capacity in grams Differing characteristics of this
refrigerant circuit
Audi 80 From 10.92 750 + 50 • None
Audi Coupé • Vehicles with 5-cyl. engine
Audi Cabriolet
650 + 50
• Vehicles with 4 or 6-cyl. engine
Note
♦ Replacement restrictors with different holes are available. If

these vehicles are fitted with a yellow-coloured restrictor, add
50 g more refrigerant than specified in the table. After charg‐
ing, amend capacity stated on label or affix label indicating
new capacity.
♦ In order to distinguish between the two restrictor versions, the
one with the smaller hole (1.54 mm) is yellow-coloured. The
restrictor with the larger hole (1.83 mm) is not coloured.
10.1.9 Capacities for Audi A4 (8D_) 1995 ►
Note
Also applies to the Audi RS 4.

• Restrictor
• Reservoir

• “Denso” or “Zexel/Valeo” air conditioner compressor ⇒ Heat‐

Vehicle model Production period Capacity in grams Differing characteristics of this
refrigerant circuit
Audi A4 From 11.94 650 + 50 • Restrictor not coloured
to 11.97
From 11.97 700 + 50 • Restrictor coloured (yellow)
• “Showa/ Keihin” condenser
(distinguishing feature
⇒ page 288 )

• “AWG” condenser (distin‐
guishing feature
⇒ page 288 )
Audi RS 4 From 05.00 onwards 650 + 50 • Restrictor coloured (yellow)
Note
♦ Restrictors with a modified hole have been installed at the fac‐

tory since November 1997 (yellow-coloured). The capacity
was increased by 50 g for vehicles with a yellow-coloured re‐
strictor.
♦ The Audi A4 was fitted with different air conditioner compres‐
sors depending on the engine and production period. Exclu‐
sive use was made at the start of production of “Zexel / Valeo”
air conditioner compressors. As of Model Year 1996, “Denso”
air conditioner compressors were gradually introduced for ve‐
hicles with 6-cylinder engines.
♦ Replacement restrictors with different holes (not coloured, yel‐
low-coloured, red-coloured) are available. If a vehicle is fitted
with a different restrictor, add more or less refrigerant depend‐
ing on type (⇒ Table). After charging, amend capacity stated
on label or affix label indicating new capacity.
♦ From November 1998 onwards, Audi A4 models have also
been fitted with “AWG” condensers (initially approx. 10000
vehicles with chassis numbers between 8DXA 065 253 and
8DXA 077 026). The specified capacity for vehicles with these
condensers differs from those with “Showa/ Keihin” condens‐
ers. The condensers can be identified on the basis of certain
characteristic features ⇒ page 288 .
♦ If the condenser installed is replaced by one with a different
part number, check the capacity indicated on the label in the
vehicle and amend if necessary or affix a label with the correct
capacity over the existing one ⇒ Heating, air conditioning;
Rep. gr. 87 ; Installation location overview - Air conditioning
catalogue .
Distinguishing features of “Showa/ Keihin” and “AWG” condens‐

ers
Different manifolds:
A - Manifold on “Showa/ Keihin” condenser
B - Manifold on “AWG” condenser

Different connections to the pressure switch.

A - Connection area on “Showa/ Keihin” condenser
B - Connection area on “AWG” condenser
10.1.10 Capacities for Audi A4 (8E_) 2001 ►,

Audi A4 Cabriolet (8H_) 2003 ►
Note
Also applies to the Audi RS 4.

• Restrictor (yellow or red-coloured).
• Reservoir
• “Denso” air conditioner compressor with air conditioner com‐
pressor regulating valve - N280- (no magnetic clutch)
Vehicle Production period Capacity in grams Differing characteristics of this refriger‐
model ant circuit
Audi A4 From 11.00 onwards 500 +/- 20 • Yellow or red-coloured restrictor
Audi RS 4 From 07.05 onwards 440 +/- 20 • Red-coloured restrictor
Note

♦ To avoid altering the cooling output of the air conditioner, only
red or yellow-coloured restrictors are to be fitted. Yellow-col‐
oured restrictors were fitted in model year 2001. Red-coloured
restrictors were introduced in model year 2002. The change
to the restrictor (on vehicles produced in model year 2001, a
red-coloured restrictor may also be fitted instead of a yellow-
coloured one) does not alter the capacity for these vehicles.
♦ At the start of production exclusive use was made of type “6
SEU 12” and “7 SEU 16” air conditioner compressors from
“Denso”. From model year 2004 onwards, different “Denso”
compressors (types “6 SEU 14” and “7 SEU 17”) have gradu‐
ally replaced the old ones ⇒ Heating, air conditioning; Rep.
♦ The Audi RS 4 is fitted with a condenser with a smaller internal
volume. The capacity for this vehicle is therefore lower than
for the other vehicles ⇒ Electronic parts catalogue .

10.1.11 Capacities for Audi A4 (8K_) 2008 ►,

Audi A5 Coupé and Sportback (8T_)
2008 ►, Audi Q5 (8R_ or 83_ for China)
2008 ►, Audi A5 Cabriolet (8F_) 2009 ►,
Audi Q5 hybrid (8R_) 2011 ►
Note
♦ Also applies for the Audi RS 4, Audi S5, Audi SQ5 and Audi
RS 5.
♦ Different capacities depending on version and production pe‐
riod (see the following tables)
♦ On certain Audi Q5 versions for China the type designation
83_ is used instead of 8R_.
♦ A label -A- indicating the refrigerant R134a capacity for the
refrigerant circuit concerned can be found in the engine com‐
partment (shown here on the front lid). This label provides
information on the refrigerant R134a capacity (for the refrig‐
erant circuit fitted in the vehicle at the factory). If this label is
missing or if you are uncertain about the correct capacity (e.g.
after the condenser has been renewed), compare the capacity
indicated on the label with the figures in the following table. If
the value on the label differs from the one in the table, renew
label -A- indicating the refrigerant R134a capacity or remove
the old capacity and record the new capacity on the label using
a waterproof pen ⇒ Electronic parts catalogue .

• Expansion valve
• Receiver
• Refrigerant line with internal heat exchanger
• Mechanically driven “Denso” air conditioner compressor with
air conditioner compressor regulating valve - N280- (and with
air conditioning system magnetic clutch - N25- from model
year 2012 onwards, depending on the engine) ⇒ Heating, air
Workshop Manual) and ⇒ Electronic parts catalogue (all ve‐
hicles except Audi Q5 hybrid).
• On vehicles with a high-voltage system (Audi Q5 hybrid): elec‐
trically driven “Denso” air conditioner compressors ⇒ Heating,
• Different condenser versions (and consequently also different
capacities for the refrigerant R134a)
♦ Capacity for Audi A4, Audi A5 and Audi A5 Cabriolet
⇒ page 292
♦ Capacity for Audi Q5 and Audi Q5 hybrid ⇒ page 295
♦ Capacity for Audi RS 4, Audi RS 5 ⇒ page 299
♦ Distinguishing features of condensers ⇒ page 300
Audi A4, Audi A5 and Audi A5 Cabriolet
Note
♦ Also applies to the Audi S5.

♦ Capacity for Audi RS 5 Cabriolet ⇒ page 299
circuit
Audi A4, Audi ♦ Audi A4, from 570 +/- 20 • Air conditioner compressor without
A5 (Coupé, 10.07 to 03.12 magnetic clutch with part number
Cabriolet and 8K0 xxx xxx (manufactured by “Denso”,
Sportback) ♦ Audi A5 Coupé type “6 SEU 14” or “7 SEU 17”)
and Sportback,
from 05.07 to • Air conditioner compressor with mag‐
03.12 netic clutch with part number
8T0 xxx xxx (manufactured by “Denso”,
♦ Audi A5 Cabrio‐ type “6 SAS 14”)
let, from 03.09 to
03.12 • Condenser with part number
8K0 xxx xxx, manufactured by “Denso”
or “Showa / Keihin” (distinguishing fea‐
tures ⇒ page 300 )
• For vehicles with 4-cyl., 6-cyl. or 8-cyl.
engine (except Audi RS 5)
From 03.12 to 550 +/- 15 • Air conditioner compressor with part

10.13 onwards number 8T0 xxx xxx (manufactured by
(gradual change- “Denso”, with and without magnetic
over; see notes) clutch, type “6 SES 14” or “6 SAS 14”)
• Condenser with part number 8T0 xxx
xxx manufactured by “Denso” or manu‐
factured by “Showa/Keihin” with same
part number and index “D” or later (dis‐
tinguishing features ⇒ page 300 )
• These condensers manufactured by
“Denso” are predominantly installed on
vehicles with a 4-cyl. engine.
• The condensers manufactured by
“Showa/Keihin” with part number 8T0
xxx xxx and index “D” or later will be
gradually installed in all vehicles with 4
or 6-cyl. engines from 10.13 onwards.

circuit
630 +/- 15 • Air conditioner compressor with part
number 8T0 xxx xxx (manufactured by
“Denso”, with and without magnetic
clutch, type “6 SES 14” or “6 SAS 14”)
• Condenser manufactured by “Showa/
Keihin” with part number 8T0 xxx xxx
and index “C” or earlier (distinguishing
features ⇒ page 300 )
xxx xxx and index “C” or earlier were
predominantly installed in vehicles with
a 6-cyl. engine up to 10.13.
• The capacity valid as of 10.13 applies if
a condenser with part number 8T0 xxx
xxx and index “D” or later is installed in‐
stead of the condenser with part number
8T0 xxx xxx and index “C” or earlier
From 10.13 on‐ 550 +/- 15 ♦ Air conditioner compressor (manufac‐

wards (gradual use) turer “Denso”) all versions, belt-driven,
with and without magnetic clutch
♦ Condenser manufactured by “Showa/
and index “D” or later (distinguishing
♦ Does not apply to certain vehicles man‐
ufactured in China, see notes.
From 06.12 on‐ 600 +/- 15 • Air conditioner compressor with part
wards (only for cer‐ number 8T0 xxx xxx (manufactured by
tain vehicles manu‐ “Denso”, with and without magnetic
factured in China; clutch, type “6 SES 14” or “6 SAS 14”)
see notes)
• Condenser with part number
8KD xxx xxx, manufactured by “Showa /
Keihin” (distinguishing features
⇒ page 300 )
• This condenser manufactured by
“Showa / Keihin” is currently only instal‐
led on vehicles produced in China.
Note
♦ Starting with the product changeover in March 2012, Audi A4

and Audi A5 vehicles (except RS models) are no longer avail‐
able with 8-cyl. engines.
♦ The air conditioner compressors fitted at the start of production
were manufactured by “Denso” (type “6 SEU 14” for vehicles
with 4-cyl. and 6-cyl. engine and type “7 SEU 17” for vehicles
with 8-cyl. engine); these air conditioner compressors do not
engine). In model year 2012, the air conditioner compressor
type “6 SEU 14” is gradually being replaced by type
“6 SES 14”. Air conditioner compressors produced by other
manufacturers may also be fitted at a later date (depending on
the engine) ⇒ Electronic parts catalogue and ⇒ Heating, air
Workshop Manual).
♦ From model year 2012 onwards, air conditioner compressors
with an additional air conditioning system magnetic clutch -
N25- on the pulley (type “6 SAS 14”) were gradually introduced
for vehicles with certain engines (e.g. vehicles with 4-cyl. TDI
parts catalogue .
♦ From August 2011 onwards, air conditioners with air condi‐
tioning system magnetic clutch - N25- are gradually being
introduced for certain 4-cyl. TDI engines ⇒ Electronic parts
catalogue .
♦ From March 2012 onwards, the refrigerant circuit (air condi‐
tioner compressor, condenser, evaporator etc.) was gradually
modified depending on the engine. This means that the refrig‐
erant and refrigerant oil capacity for these vehicles has also
changed (indicated on label for refrigerant circuit)
⇒ page 336 ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐
frigerant circuit (vehicle-specific Workshop Manual) and ⇒
♦ From June 2012 onwards, condensers manufactured by
“Showa / Keihin” (part number 8KD xxx xxx) are gradually be‐
ing installed on vehicles produced in China. This condenser
has a different internal design, thus resulting in a different re‐
frigerant capacity. Identification ⇒ page 300
♦ From October 2013 onwards, condensers manufactured by
“Showa/Keihin” with part number 8T0 xxx xxx and index “D” or
later are gradually being installed in all vehicles (apart from the
RS models). This condenser has a different structure (flat
tubes are not as high (1.5 mm instead of 2.0 mm), therefore
the internal volume is smaller) than the condenser manufac‐
tured by “Showa/Keihin” with part number 8T0 xxx xxx and
index “C” or earlier, therefore the refrigerant capacity is also
different. Identification ⇒ page 300
♦ If a condenser manufactured by “Showa/Keihin” with part
number 8T0 xxx xxx and index “D” or later or a condenser
manufactured by “Denso” is installed in a vehicle in which a
condenser manufactured by “Showa/Keihin” with part number
8T0 xxx xxx and index “C” or earlier (or a condenser with part
number 8K0 xxx xxx or 8KD xxx xxx) was previously installed,
then the capacity valid for this condenser must be added (see
table). The same applies if a condenser manufactured by
“Denso” is replaced with a condenser with a different manu‐
facturer or part number. In addition, the capacity specified on
the label in the vehicle is to be checked and amended if nec‐
essary or the existing label is to be replaced with one indicating
the correct capacity (affix over old label).

♦ From the outside, the modified components (air conditioner

compressor, condenser) can only be identified by the part
numbers (label on air conditioner compressor, type plate or
lettering on condenser) ⇒ page 300 and ⇒ Electronic parts
catalogue .
Audi Q5 and Audi Q5 hybrid
Note
Also applies for the Audi SQ5.
circuit
Audi Q5 From 09.08 to 570 +/- 20 • Air conditioner compressor without
06.12 / 08.12 (grad‐ magnetic clutch with part number
ual change-over; 8K0 xxx xxx (manufactured by “Denso”,
see notes) type “6 SEU 14”)
• Air conditioner compressor with mag‐
netic clutch with part number
8T0 xxx xxx (type “6 SAS 14”)
8K0 xxx xxx, manufactured by “Denso”
or “Showa / Keihin” (distinguishing fea‐
tures ⇒ page 300 )
From 06.12/08.12 550 +/- 15 • Air conditioner compressor with part

to 10.13 (gradual number 8T0 xxx xxx (manufactured by
change-over; see “Denso”, with and without magnetic
notes) clutch, type “6 SES 14” or “6 SAS 14”)
• Condenser with part number 8T0 xxx
xxx manufactured by “Denso” or manu‐
factured by “Showa/Keihin” with same
part number and index “D” or later (dis‐
tinguishing features ⇒ page 300 )
• The condensers manufactured by “Den‐
so” are not currently being installed in
the Audi Q5 (mainly installed in the Audi
A4 and Audi A5 with 4-cyl. engine; no
decision has been made about use in
the Audi Q5). Identification
⇒ page 300
xxx xxx and index “D” or later will be
gradually installed in all vehicles from
10.13 onwards.
circuit
From 06.12/08.12 630 +/- 15 • Air conditioner compressor with part
to 10.13 (gradual number 8T0 xxx xxx (manufactured by
change-over; see “Denso”, with and without magnetic
notes) clutch, type “6 SES 14” or “6 SAS 14”)
• Condenser manufactured by “Showa/
and index “C” or earlier (distinguishing
xxx xxx and index “C” or earlier will be
installed in the Audi Q5 as of the
change-over on 06.12 or 08.12 (no de‐
cision has been made about the use of
the “Denso” condenser in the Audi Q5;
see below for vehicles manufactured in
China).
• The capacity valid as of 10.13 applies if
a condenser with part number 8T0 xxx
xxx and index “D” or later is installed in‐
stead of the condenser with part number
8T0 xxx xxx and index “C” or earlier
From 10.13 on‐ 550 +/- 15 ♦ Air conditioner compressor (manufac‐

wards (gradual use) turer “Denso”) all versions, belt-driven,
with and without magnetic clutch
♦ Condenser manufactured by “Showa/
and index “D” or later (distinguishing
♦ Does not apply to certain vehicles man‐
ufactured in China, see notes.
From 08.12 on‐ 600 +/- 15 • Air conditioner compressor with part
wards (only for cer‐ number 8T0 xxx xxx (manufactured by
tain vehicles manu‐ “Denso”, with and without magnetic
factured in China; clutch, type “6 SES 14” or “6 SAS 14”)
see notes)
8KD xxx xxx, manufactured by “Showa /
Keihin” (distinguishing features
⇒ page 300 )
• The condenser manufactured by
“Showa/Keihin” with part number 8KD
xxx xxx is currently only installed in ve‐
hicles produced in China.
• If a condenser with another part number
(e.g. 8T0 xxx xxx and index “D” or later)
is installed instead of the condenser with
part number 8KD xxx xxx, the capacity
specified for this condenser applies.

circuit
Audi Q5 hy‐ From 05.11 to 840 +/- 20 (see notes) • Electrically driven air conditioner com‐
brid 07.12 (see notes) pressor
8R0 xxx xxx, manufactured by
“Denso” (distinguishing features
⇒ page 300 )
• Air conditioner operating and display
unit ( Climatronic control unit - J255-
with part number 8Rx xxx xxx and an air
conditioning unit with part number 8Kx
xxx xxx ⇒ Electronic parts catalogue
and ⇒ Heating, air conditioning; Rep.
gr. 87 ; Refrigerant circuit (vehicle-spe‐
• With second evaporator in battery cool‐
ing module
From 07.12 on‐ 900 +/- 15 • Electrically driven air conditioner com‐
wards ♦ The refrigerant capacity pressor
of these vehicles was • Condenser with part number
originally 840 g from 8R0 xxx xxx, manufactured by
07.12 to 10.13, but this “Denso” (distinguishing features
was then increased to ⇒ page 300 )
900 g (see notes).
• Air conditioner operating and display
unit ( Climatronic control unit - J255-
with part number 8Kx xxx xxx and an air
conditioning unit with part number 8Tx
xxx xxx ⇒ Electronic parts catalogue
and ⇒ Heating, air conditioning; Rep.
gr. 87 ; Refrigerant circuit (vehicle-spe‐
ing module
Note
♦ At the start of production, all vehicles (except the Audi Q5 hy‐

brid) are fitted with a mechanically driven air conditioner com‐
pressor manufactured by “Denso” (e.g. type “6 SEU 14”);
these air conditioner compressors do not have a magnetic
clutch (they are driven continuously by the engine). In model
year 2012, the air conditioner compressor type “6 SEU 14” is
gradually being replaced by type “6 SES 14”. Air conditioner
parts catalogue .
♦ From August 2011 onwards, air conditioners with air condi‐
tioning system magnetic clutch - N25- are gradually being
catalogue .
♦ From June 2012 onwards, the refrigerant circuit (air condition‐
er compressor, condenser, evaporator etc.) was gradually
changed (indicated on label for refrigerant circuit) ⇒ Heating,
♦ From June 2012 onwards, condensers manufactured by
“Showa/Keihin” (part number 8KD xxx xxx) are gradually being
installed on vehicles produced in China. This condenser has
a different internal design, thus resulting in a different refrig‐
erant capacity. Identification ⇒ page 300
♦ From October 2013 onwards, condensers manufactured by
RS models). This condenser has a different structure (flat
tubes are not as high (1.5 mm instead of 2.0 mm), therefore
the internal volume is smaller) than the condenser manufac‐
tured by “Showa/Keihin” with part number 8T0 xxx xxx and
index “C” or earlier, therefore the refrigerant capacity is also
different. Identification ⇒ page 300
♦ If a condenser manufactured by “Showa/Keihin” with part
number 8T0 xxx xxx and index “D” or later or a condenser
manufactured by “Denso” is installed in a vehicle in which a
condenser manufactured by “Showa/Keihin” with part number
8T0 xxx xxx and index “C” or earlier (or a condenser with part
number 8K0 xxx xxx or 8KD xxx xxx) was previously installed,
then the capacity valid for this condenser must be added (see
table). The same applies if a condenser manufactured by
“Denso” is replaced with a condenser with a different manu‐
facturer or part number. In addition, the capacity specified on
the label in the vehicle is to be checked and amended if nec‐
essary or the existing label is to be replaced with one indicating
the correct capacity (affix over old label).
lettering on condenser) ⇒ page 300 and ⇒ Electronic parts
catalogue .

♦ At the start of production, the Audi Q5 hybrid is fitted with an

electrically driven “Denso” air conditioner compressor ( elec‐
trical air conditioner compressor - V470- with control unit for
air conditioning compressor - J842- ). There is no provision for
an air conditioner compressor regulating valve - N280- on this
air conditioner compressor.
♦ From October 2013 onwards, the refrigerant quantity for the
refrigerant circuit on the Audi Q5 Hybrid was increased from
840 g to 900 g. The increased quantity of refrigerant applies
retroactively to all vehicles from July 2012 onwards with an
operating and display unit for the air conditioning, the control
unit for Climatronic - J255- with part number 8Kx xxx xxx and
an air conditioning unit with part number 8Tx xxx xxx (different
software and different evaporator in the air conditioning unit)
with the next filling. The refrigerant circuit does not have to be
specially emptied to fill it with the increased quantity. It is
enough to pour in the increased quantity e.g. after performing
an operation on the refrigerant circuit for which emptying and
refilling is required anyway. On vehicles manufactured up to
October 2013, check whether the increased quantity of refrig‐
erant has already been added during a previous workshop visit
and the indicated capacity on the label has been changed. If
not, check the refrigerant capacity on the label and if neces‐
sary stick on a new label with the correct capacity and lan‐
guage ⇒ Electronic parts catalogue and ⇒ Heating, air
conditioning; Rep. gr. 87 ; Installation location overview - Air
conditioning (vehicle-specific Workshop Manual). If no label
with the correct capacity and the appropriate language is avail‐
able, alter the capacity indicated on the existing label accord‐
ingly with a waterproof pen. If necessary, subsequently fill the
refrigerant circuit with the higher refrigerant quantity indicated
above.
Audi RS 4, Audi RS 5
Note
Also applies for the Audi RS 5 Cabriolet.
circuit
Audi RS 4 and ♦ RS 4 from 05.12 570 +/- 20 • Air conditioner compressor without
Audi RS 5 onwards magnetic clutch with part number
8K0 xxx xxx (manufactured by “Denso”,
♦ RS 5 from 03.10 type “7 SEU 17”)
onwards
8K0 xxx xxx, manufactured by
“Denso” (distinguishing features
⇒ page 300 )
Note

were manufactured by “Denso” (type “7 SEU 17”); these air
conditioner compressors do not have a magnetic clutch (they
are driven continuously by the engine via a shaft). Air condi‐
tioner compressors produced by other manufacturers may
also be fitted at a later date (depending on the engine) ⇒
Electronic parts catalogue and ⇒ Heating, air conditioning;
Manual).
♦ On the Audi RS 4 and RS 5 there is no changeover of the
refrigerant circuit in model year 2012 (see other versions).
Distinguishing features of condensers
Note
♦ Different condensers are installed in these vehicles depending

on the production period, vehicle version and engine ⇒ Elec‐
tronic parts catalogue . The distinguishing features of these
condensers are the internal design and the internal volume.
This means that the capacity of the refrigerant circuit varies
depending on the condenser. Therefore it is important to ob‐
serve the version of the condenser when determining the
refrigerant capacity.
♦ Currently condensers by different manufacturers (“Denso” and
“Showa/Keihin”) are installed; they can be identified by certain
features.
♦ The design of condensers by one manufacturer can also vary;
from the outside this can only be identified by the part number.
Due to the differences in design (flow distribution, internal vol‐
ume), the refrigerant capacity for the refrigerant circuit varies
⇒ page 27 .
♦ These condensers are available in different versions with dif‐
ferent designs (can be identified e.g. by part numbers
8K0 xxx xxx , 8Rx xxx xxx, 8KD xxx xxx or 8T0 xxx xxx)
⇒ page 27 ; for the correct version refer to the ⇒ Electronic
parts catalogue .

Features of a condenser manufactured by “Denso” -A-

♦ End strip (top) -B-: U-profile
♦ Part number and data of condenser manufacturer -C- (cur‐
rently printed on directly); allocation ⇒ Electronic parts cata‐
logue
♦ Receiver -D- integrated in condenser (desiccant cartridge can
be renewed after removing plastic plug/cap -E-) ⇒ Heating,
Features of a condenser manufactured by “Showa/Keihin” -A-

♦ End strip (top) -B-: flat profile
♦ Part number and data of condenser manufacturer -C- (cur‐
rently on a label bonded on); allocation ⇒ Electronic parts
catalogue
♦ Receiver -D- attached to condenser (receiver -D- can be re‐
newed after removing bolts -E-) ⇒ Heating, air conditioning;
Manual).
Note
From October 2013 onwards, condensers manufactured by

RS models). This condenser has a different structure (flat tubes
are not as high (1.5 mm instead of 2.0 mm), therefore the internal
volume is smaller) than the condenser manufactured by “Showa/
Keihin” with part number 8T0 xxx xxx and index “C” or earlier,
therefore the refrigerant capacity is also different. The only way
to tell these condensers apart is by the part number; there is no
way to unambiguously determine the different flat tube heights
using workshop equipment.
10.1.12 Capacities for Audi A4 (8W_) 2016 ►,

Audi A4 (86_ for China) 2017 ►, Audi A5
(F5_) 2016 ►, Audi Q5 (FY_) 2017 ►,
Audi Q5 (87_ for China) 2019 ►
Note
Also applies for Audi A4 allroad, Audi A4 (type 86_ for China),
Audi A5 (all versions), Audi Q5 (type 87_ for China) as well as S
and RS models.

• Expansion valve
• Receiver
N280- , with or without air conditioning system magnetic clutch
- N25- (depending on engine) ⇒ Heating, air conditioning;
Manual) and ⇒ Electronic parts catalogue .
Vehicle Production Capacity in Differing characteristics
model period grams of this refrigerant circuit
Audi A4 From 590 +/- 15 • None
Audi A5 07.15 on‐
Audi wards
Q5
10.1.13 Capacities for Audi 100/Audi A6 (4A_) ► 1998

• Restrictor not coloured
• Reservoir
Vehicle mod‐ Production period Capacity in grams Differing characteristics of this refriger‐
el ant circuit
Audi 100 / From 10.92 750 + 50 • None
Audi A6 to 03.97

Note
♦ If a vehicle is fitted with a yellow-coloured restrictor as re‐

placement for a non-coloured restrictor, add 50 g more refrig‐
erant than specified in the table. In addition, the capacity
specified on the label in the vehicle is to be checked and
amended if necessary or the existing label is to be replaced
with one indicating the correct capacity (affix over old label).
♦ Restrictors with modified hole (coloured) have been installed
at the factory since November 1997. In order to distinguish
between the two restrictor versions, the one with the smaller
hole (1.54 mm) is yellow-coloured. The restrictor with the larg‐
er hole (1.83 mm) is not coloured.
♦ The Audi 100 / Audi A6 features different air conditioner com‐
pressors depending on the engine and production period.
Exclusive use was made at the start of production of “Zexel /
Valeo” air conditioner compressors. As of Model Year 1996,
“Denso” air conditioner compressors were gradually intro‐
duced for vehicles with 6-cylinder engines.
♦ The air conditioner compressor designation “Zexel / Valeo”
was changed as of 2006 to “Valeo”.
♦ From September 1994, production was gradually switched
from condenser 4A0 260 403 AB to condenser 4A0 260 403
AC.
♦ The refrigerant capacity of 750+50 g applies to all Audi 100
models (regardless of condenser).
♦ Only condensers with part number 4A0 260 403 AC are now
available as replacement parts (if necessary make use of la‐
bel, part no. 8A0 010 126 P).
♦ After charging the refrigerant circuit of vehicles manufactured
up to October 1994, check the capacity stated on the label in
the vehicle and amend if necessary or affix the label, part no.
8A0 010 126 P over the existing label (modified capacity) ⇒
Heating, air conditioning; Rep. gr. 87 ; Installation location
overview - Air conditioning (vehicle-specific Workshop Man‐
ual) and ⇒ Electronic parts catalogue .
10.1.14 Capacities for Audi A6 (4B_) 1998 ► and Audi allroad (4B_) ► 2005
• Restrictor
• Reservoir
• “Denso” or “Zexel / Valeo” air conditioner compressor ⇒ Heat‐
ing, air conditioning; Rep. gr. 87 ; Installation location over‐
view - Air conditioning (vehicle-specific Workshop Manual)
and ⇒ Electronic parts catalogue
circuit
to 11.97
• Air conditioner unit version “1” ⇒
Heating, air conditioning; Rep. gr. 87 ;
Installation location overview - Air
conditioning (vehicle-specific Work‐
shop Manual).
• Condenser with flat tube dimensions
20 mm x 3 mm ⇒ page 308

to 08.98
• Air conditioner unit version “1” ⇒
shop Manual).
• Condenser with flat tube dimensions
20 mm x 3 mm ⇒ page 308
Note

was increased by 50 g for vehicles in which a yellow-coloured
restrictor was installed.
♦ If a vehicle is fitted with a coloured restrictor as replacement
for a non-coloured restrictor, add 50 g more refrigerant (see
table). In addition, the capacity specified on the label in the
vehicle is to be checked and amended if necessary or the ex‐
isting label is to be replaced with one indicating the correct
capacity (affix over old label).
♦ The Audi A6 is fitted with different air conditioner compressors
depending on the engine and production period.
♦ In August/September 1998, production was gradually switch‐
ed from air conditioning unit version “1” to air conditioning unit
version “2”. A reduction in capacity was achieved as the evap‐
orator was also modified together with the air conditioning unit.
♦ The two air conditioning unit versions can be identified on the
basis of certain characteristics described in the vehicle-spe‐
cific Workshop Manual ⇒ Heating, air conditioning; Rep. gr.
87 ; Installation location overview - Air conditioning (vehicle-
specific Workshop Manual) and ⇒ Electronic parts catalogue .

Vehicle model Production period Capacity in grams Differing characteristics of this refriger‐
ant circuit
Audi A6 From 08.98 750 + 50 • Restrictor coloured (yellow)
• With 4-cyl. to 04.99
engine • Air conditioner unit version “2” ⇒
Heating, air conditioning; Rep. gr.
• With 6-cyl. 87 ; Installation location overview -
petrol en‐ Air conditioning (vehicle-specific
gine Workshop Manual).
• Condenser with part no. 4B0 260
401 (403) and index “D”, “E” or
“F” (flat tube dimensions 20 mm x 3
mm ⇒ page 308 ) ⇒ Electronic parts
catalogue .
Audi A6 ♦ From 08.98 to 10.98 750 + 50 • Restrictor coloured (yellow)

• With 6-cyl.
diesel en‐ ♦ From 12.98 to 10.99 • Air conditioner unit version “2” ⇒
gine (see notes) Heating, air conditioning; Rep. gr.
87 ; Installation location overview -
Air conditioning (vehicle-specific
Workshop Manual).
• Condenser with part no. 4B0 260
401 (403) and index “D”, “E” or
“F” (flat tube dimensions 20 mm x 3
mm ⇒ page 308 ) ⇒ Electronic parts
catalogue .
circuit
Audi A6/ ♦ From 10.98 to 12.98 550 + 50 • Restrictor coloured (yellow)
Audi allroad
• With 6-cyl. ♦ From 10.99 onwards • Air conditioner unit version “2 or 3” ⇒
diesel en‐ (see notes) Heating, air conditioning; Rep. gr. 87 ;
gine Installation location overview - Air
shop Manual).
• Condenser with part no. 4B0 260 401
(403) and index “G” or “R” (flat tube
dimensions 16 mm x 1.7 mm
⇒ page 308 ) and ⇒ Electronic parts
catalogue
Audi A6/ From 04.99 650 + 50 • Restrictor coloured (yellow)

Audi allroad
• With 4-cyl. • Air conditioner unit version “2 or 3” ⇒
engine ex‐ Heating, air conditioning; Rep. gr. 87 ;
cept 2.0 ltr. Installation location overview - Air
• With 6-cyl. shop Manual).
petrol en‐
gine ex‐ • Condenser with part no. 4B0 260 401
cept 3.0 ltr. (403) and index “H”, “J”, “K”, “S”, “T”
engine or “N” (flat tube dimensions 18 mm x
1.7 mm ⇒ page 308 ) and ⇒ Elec‐
• With 6-cyl. tronic parts catalogue .
diesel en‐
gine (see
notes)
circuit
Audi A6 From 05.01 onwards 550 + 50 • Restrictor coloured (yellow)
• With 2.0
ltr. 4-cyl. • Air conditioner unit version “3” ⇒
engine Heating, air conditioning; Rep. gr. 87 ;
• With 3.0 conditioning (vehicle-specific Work‐
ltr. 6-cyl. shop Manual).
engine
• Condenser with part no. 8E0 260 401
(403) and index A (flat tube dimen‐
sions 18 mm x 1.7 mm ⇒ page 308 )
• Air conditioner compressor regulating
valve - N280-
Note
♦ Condensers with air conditioning system pressure switch -

F129- or high-pressure sender - G65- are supplied for factory
use as part no. XXX XXX 401 X. This condenser is supplied
without an air conditioning system pressure switch - F129- or
high-pressure sender - G65- for replacement purposes as part
no. XXX XXX 403 X.
♦ From 10.98 to 12.98 vehicles with 6-cyl. diesel engine (initially
about 10000) were fitted with condensers of a different design.
The capacity is different for vehicles with these condensers.
The condensers can be identified on the basis of certain char‐
acteristics and the part number ⇒ page 308 .
♦ When renewing a condenser, pay attention to the index of the
part number (different flat tube versions, flat tube dimensions
16 mm x 1.7 mm, 18 mm x 1.7 mm or 20 mm x 3 mm) and the
different capacities. If a condenser with a different part number
index is installed, the capacity specified on the label must be
checked and amended if necessary or a label indicating the
modified capacity must be affixed over the existing label. The
part number can be found on a sticker attached to the bottom
of the condenser.
♦ From 04.99 onwards, production was gradually switched from
condensers with flat tube dimensions 20 mm x 3 mm to con‐
densers with flat tube dimensions 18 mm x 1.7 mm or 16 mm
x 1.7 mm. The change in production took place gradually dur‐
ing the course of 1999 depending on the engine and existing
supplies of the different versions. Refer to the Electronic parts
catalogue for precise assignment of the different condensers
♦ Vehicles with 6-cyl. diesel engine produced from 04.99 on‐
wards may be equipped with a condenser with index “D”, “G”,
“R” or “K”. Observe the different capacities ⇒ Heating, air
conditioning (vehicle-specific Workshop Manual) and ⇒ Elec‐

circuit
Audi A6 • Up to 03.99 550 + 50 • Restrictor coloured (yellow)
• With 8-cyl.
engine And again • Air conditioner unit version “2 or 3” ⇒
• From 02.00 on‐ Heating, air conditioning; Rep. gr. 87 ;
wards Installation location overview - Air
shop Manual).
(403) B, D, E (flat tube dimensions 18
mm x 1.7 mm ⇒ page 308 ) ⇒ Elec‐
Audi A6 From 03.99 to 02.00 650 + 50 • Restrictor coloured (yellow)

• With 8-cyl.
engine • Air conditioner unit version “2” ⇒
shop Manual).
(403) C (flat tube dimensions 18 mm
x 1.7 mm ⇒ page 308 ) ⇒ Electronic
parts catalogue .
Note
♦ The Audi A6 with 8-cyl. engine is fitted with “Denso” air con‐
ditioner compressors.
♦ In August/ September 1998 production was gradually switch‐
ed from air conditioning unit version “1” to air conditioning unit
version “2”. Vehicles with an 8-cyl. engine are only fitted with
air conditioning unit from version “2” onwards.
♦ The different air conditioning unit versions can be identified on
the basis of certain characteristics described in the Workshop
Manual ⇒ Heating, air conditioning; Rep. gr. 87 ; Installation
shop Manual).
♦ Different condensers were installed in vehicles with 8-cylinder
engines. Exclusive use was made for USA vehicles of con‐
densers with part no. 4B3 260 401 (403) C, D, E.
♦ In March 1999, production was gradually switched from con‐
densers with part number 4B3 260 401 (403) B to condensers
with part number 4B3 260 401 (403) C.
♦ If the condenser fitted is replaced by one with a different part
number, amend the capacity specified on the label or affix a
label with the modified capacity over the existing label. The
part number can be found on a sticker attached to the bottom
of the condenser ⇒ Heating, air conditioning; Rep. gr. 87 ;
Installation location overview - Air conditioning (vehicle-spe‐
Deduct the flat tube dimensions from the condenser
Note
♦ Production was gradually switched from calendar week 45,

1998 onwards (initially for Audi A6 with 6-cyl. diesel engine) to
a condenser with smaller flat tubes.
♦ Pay attention to the part number when renewing a condenser
(sometimes the only distinguishing feature) ⇒ Electronic parts
catalogue .
Condensers -A- with flat tube dimensions -B- = 20 mm and -C- =

3.0 mm must be filled with more refrigerant than condensers -D-
with flat tube dimensions -E- = 18 mm or 16 mm and -F- = 1.7 mm
Pay attention to flat tube dimensions if condenser is renewed. If

a condenser with different dimensions is to be fitted, also renew
label -A- indicating the refrigerant R134a capacity or remove the
old capacity and record the new capacity using a waterproof pen
10.1.15 Capacities for Audi A6 (4F_) 2005 ►
Note
Also applies to the Audi S6 and Audi RS 6.

• Restrictor (red-coloured).
• Reservoir
pressor regulating valve - N280- (no magnetic clutch)

Vehicle Production period Capacity in grams Differing characteristics of this refriger‐

model ant circuit
Audi A6/ From 04.04 onwards 530 +/- 20 • Red-coloured restrictor
S6
Audi RS 6 From 05.08 onwards 500 +/- 20 • Red-coloured restrictor
• Condenser with smaller internal
volume
Note

red-coloured restrictors are to be fitted.
♦ Different air conditioner compressors are fitted depending on
the model ⇒ Heating, air conditioning; Rep. gr. 87 ; Installation
♦ The condenser fitted on vehicles with a 10-cyl. TFSI engine
(Audi RS 6) has a smaller internal volume than the condenser
with other engines. For vehicles with a 10-cyl. TFSI engine the
refrigerant capacity is thus also slightly less than for other ve‐
hicles ⇒ Electronic parts catalogue .
10.1.16 Capacities for Audi A6 (4G_ or 4X_ for

China ) 2011 ►, Audi A7 (4G_ or 4X_ for
China) 2011 ►, Audi A6 hybrid (4G_)
2012 ►, A6 e-tron (4G_) 2017 ►
Note
♦ Also applies to Audi S and RS models.

♦ RS models are fitted with a shallower condenser ⇒ Heating,

• Expansion valve
• Receiver
hicles except Audi A6 hybrid).
• On vehicles with a high-voltage system (Audi A6 hybrid): elec‐

• On vehicles with a high-voltage system (Audi A6 e-tron): elec‐
trically driven “Sanden” air conditioner compressors ⇒ Heat‐
circuit
Audi A6 From 02.11 on‐ 570+ / - 20 • None
wards
Audi A7 From 10.10 on‐ 570+ / - 20 • None
wards
Audi RS 6 / From 01.13 on‐ 540+ / - 20 • Condenser with smaller internal volume
RS 7 wards
Audi A6 hy‐ From 11.11 on‐ 860+/- 15 (see notes) • Electrically driven air conditioner com‐
brid wards pressor
ing module
Audi A6 e-tron From 09.16 on‐ 1000+ / - 15 • Electrically driven air conditioner com‐
wards pressor
• With second evaporator in high-voltage
battery heat exchanger

Note

instead of 4G_.
♦ At the start of production, all vehicles except the Audi A6 hybrid
(Audi A6 e-tron) were fitted with mechanically driven air con‐
ditioner compressors manufactured by “Denso”. Air condition‐
er compressors produced by other manufacturers may also be
fitted at a later date ⇒ Electronic parts catalogue and ⇒ Heat‐
♦ At the start of production, the Audi A6 hybrid is fitted with an
♦ At the start of production, the Audi A6 e-tron is fitted with an
electrically driven “Sanden” air conditioner compressor ( elec‐
♦ At the start of production, the Audi A6 hybrid was fitted with an
air conditioner compressor with a refrigerant oil quantity of
200 ccm. A capacity of 840 +/- 15 g for refrigerant was planned
at the factory for these vehicles (specification on label for re‐
frigerant). Shortly after the start of production, the refrigerant
oil quantity was reduced to 160 ccm and the refrigerant quan‐
tity was raised to 860 +/- 15 g. In after-sales service, a quantity
of 860 +/- 15 g of refrigerant always applies for this vehicle
irrespective of the refrigerant oil quantity (if necessary, change
capacity specification on label with a water-proof pen).
♦ In contrast to vehicles with other engines, on Audi RS 6 / RS
7 a condenser with a smaller internal volume is installed;
therefore the refrigerant capacity for these vehicles is slightly
lower than for other vehicles in this series ⇒ Electronic parts
catalogue .
10.1.17 Capacities for Audi V8 (4C_) ► 1994

• Reservoir
el ant circuit
Audi V8 From 10.92 850 + 50 • None
to 10.93
Note
♦ Replacement restrictors with different holes are available. If

these vehicles are fitted with a yellow-coloured restrictor, add
50 g more refrigerant than specified in the table. After charg‐
ing, amend capacity stated on label or affix label indicating
new capacity.
♦ In order to distinguish between the different restrictor versions,
the ones with a smaller hole are coloured (yellow or red). The
red-coloured restrictor is not to be used for these vehicles.

• Restrictor
• Reservoir
el ant circuit
to 11.97

Note

was increased by 50 g for vehicles with a yellow-coloured re‐
strictor.
♦ In order to distinguish between the different restrictor versions,
the one with the smaller hole is coloured yellow (1.54 mm) or
red (1.42 mm). The restrictor with the larger hole (1.83 mm) is
not coloured.
♦ If a vehicle is fitted with a yellow-coloured restrictor as re‐
placement for a non-coloured restrictor, add 50 g more refrig‐
erant (see table). In addition, the capacity specified on the
label in the vehicle is to be checked and amended if necessary
or the existing label is to be replaced with one indicating the
correct capacity (affix over old label). The red-coloured re‐
strictor is not to be used for these vehicles.
♦ Exclusive use was made at the start of production of “Zexel /
Valeo” air conditioner compressors. From model year 1996
onwards, production was gradually switched to “Denso” air
conditioner compressors ⇒ Heating, air conditioning; Rep. gr.
10.1.19 Capacities for Audi A8 (4E_) 2003 ►

• Reservoir
pressor regulating valve - N280- (without magnetic clutch) ⇒
el ant circuit
Audi A8 From 10.02 onwards 620 +/- 20 • Red-coloured restrictor
Note

version ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
parts catalogue .
10.1.20 Capacities for Audi A8 (4H_) 2010 ►, Audi A8 hybrid (4H_) 2012 ►
• Expansion valve
• With one or two evaporator(s) depending on equipment
• Desiccant cartridge in receiver at condenser
air conditioner compressor regulating valve - N280- ⇒ Heat‐
(all vehicles except Audi A8 hybrid).
Caution
Different refrigerant and refrigerant oil capacities for vehicles

with 8-cyl. TDI engine
♦ For vehicles with 8-cylinder TDI engine: Due to the fitting
location of the air conditioner compressor at the top of the
engine, the amount of refrigerant oil required differs from
the quantity indicated on the factory label of the air condi‐
tioner compressor.
circuit
Audi A8 (all From 03.10 on‐
engines ex‐ wards
cept 8-cyl.
TDI)
♦ Vehicle 780 +/- 20 • One evaporator
with one
evaporator
♦ Vehicle 930 +/- 20 • Two evaporators

with two
evapora‐
tors
Audi A8 (only From 03.10 on‐

8-cyl. TDI en‐ wards
gine)
♦ Vehicle 740 +/- 15 • One evaporator
with one
evaporator
♦ Vehicle 915 +/- 15 • Two evaporators

with two
evapora‐
tors

circuit
Audi A8 hy‐ From 01.12 on‐ 1080 +/- 15 • One evaporator in air conditioning unit
brid wards
• Electrically driven air conditioner com‐
pressor
• Second evaporator in battery cooling
module
Note
♦ For vehicles with 8-cyl. TDI engine, the quantity of refrigerant

oil in the refrigerant circuit was increased as of vehicle identi‐
fication number 4H_ BN 018846 and the refrigerant capacity
had to be accordingly reduced slightly. As the capacity spec‐
ification on the label has not yet been changed, proceed as
follows: On vehicles manufactured up to the vehicle identifi‐
cation number mentioned, check whether the refrigerant oil
has already been topped up during a previous workshop visit.
If not, add 50 ccm of refrigerant oil to the refrigerant circuit.
Then correspondingly alter the refrigerant capacity specified
on the label in waterproof ink and fill the refrigerant circuit with
the quantity of refrigerant stated above. Finally make a record
of the change made in the vehicle data. On vehicles manu‐
factured as of the vehicle identification number mentioned,
check the refrigerant capacity specified on the label, alter ac‐
cordingly in waterproof ink if applicable and then fill the refrig‐
erant circuit with the quantity of refrigerant specified above.
were fitted with mechanically driven air conditioner compres‐
sors manufactured by “Denso”. Air conditioner compressors
produced by other manufacturers may also be fitted at a later
date ⇒ Electronic parts catalogue and ⇒ Heating, air condi‐
shop Manual).
200 ccm. Shortly after the start of production, the refrigerant
oil quantity was reduced to 160 ccm. In after-sales service, a
quantity of 1080 +/- 15 g of refrigerant always applies for this
vehicle irrespective of the refrigerant oil quantity (if necessary,
change capacity specification on label with a water-proof pen).
10.1.21 Capacities for Audi Q7 (4L_) 2006

Audi Q7 (4L_) 2006 ►
• Expansion valve
• Denso air conditioner compressor with air conditioner com‐
pressor regulating valve - N280- ⇒ Heating, air conditioning;

Manual) and ⇒ Electronic parts catalogue
circuit
Audi Q7 (4L_) From 02.06 on‐
wards
♦ Vehicle 700 + 50 • One evaporator
with one
evaporator
♦ Vehicle 1050 + 50 • Two evaporators

with two
evapora‐
tors
10.1.22 Capacities for Audi Q7 (4M_) 2016 ►

The refrigerant R134a capacities can be found in the vehicle-
specific Workshop Manual ⇒ Heating, air conditioning; Rep. gr.
00 ; Technical data; Capacities for refrigerant R1234yf .
Note
♦ On the Audi Q7 e-tron, additional components (which are not

fitted on other vehicles) are installed in the refrigerant circuit.
For the layout of the different refrigerant circuits, refer to ⇒
♦ As the service connection on the high-pressure side is located
in the refrigerant circuit, high pressure is only available at the
service connection on the high-pressure side during operation
of the refrigerant circuit on the Audi Q7 e-tron. When operating
the air conditioner, the same pressure is available here as at
the service connection on the low-pressure side.
♦ In order to discharge, evacuate and fill the refrigerant circuit
on the Audi Q7 e-tron, the electrically actuated valves installed
in the refrigerant circuit must be open. The valves must be
activated and opened via a routine stored in the thermal man‐
agement control unit - J1024- ⇒ Heating, air conditioning;
Manual) and ⇒ Vehicle diagnostic tester in “Guided Fault Find‐
ing” mode.
10.1.23 Capacities for Audi R8 (42_) 2008 ►, Audi R8 (4S_) 2015 ►

Characteristics of refrigerant circuit for Audi R8 (42_) 2008 ►:
• Reservoir
• Two condensers (connected in series)
Characteristics of refrigerant circuit for Audi R8 (4S_) 2015 ►:
• Expansion valve
• Receiver (with dryer)


el ant circuit
Audi R8 From 03.07 to 11.12 680 +/- 20 • Red-coloured restrictor
(42_) ♦ The refrigerant capacity
of these vehicles was
originally 650 g, but this
was then increased to
680 g (see notes)
From 11.12 onwards 680 +/- 20

Audi R8 From 08.15 onwards 820 +/- 15 • Expansion valve
(4S_)
• Receiver (with dryer) as separate
component
Note

♦ From vehicle identification number 429 DN 000751 onwards
(manufactured from 11.2013), the quantity of refrigerant in the
circuit was increased from 650 g to 680 g and the quantity of
refrigerant oil from 150 ccm to 200 ccm. The increased amount
of refrigerant and refrigerant oil also applies to all earlier ve‐
hicles. On vehicles manufactured up to the vehicle identifica‐
tion number mentioned, check whether the refrigerant oil has
already been topped up during a previous workshop visit. If
not, add 50 ccm of refrigerant oil to the refrigerant circuit. Then
check the refrigerant capacity indicated on the label and if
necessary attach a new label with the correct capacity and the
appropriate language (e.g. the label with part number
420 010 535 and index BA in German and English) ⇒ Elec‐
gr. 87 ; Installation location overview - Air conditioning (vehi‐
cle-specific Workshop Manual). If no label with the correct
capacity and the appropriate language is available, alter the
capacity indicated on the existing label accordingly with a wa‐
terproof pen. Then increase the refrigerant oil quantity in the
refrigerant circuit by 50 ccm and charge the refrigerant circuit
with the quantity of refrigerant shown above
⇒ “10.2.25 Capacities for Audi R8 (42_) 2008 ►, Audi R8 (4S_)
2015 ►”, page 358 .
10.2 Approved refrigerant oils and refrigerant

oil capacities
• On vehicles from Audi A8 (4N) 2018 onwards, information on
approved refrigerant oils and refrigerant oil capacities can be
found in the vehicle-specific Workshop Manual ⇒ Heating, air
conditioning; Rep. gr. 00 ; Technical data .
Note
♦ PAG (polyalkylene glycol) oil is highly hygroscopic (attracts

water); open containers should therefore be closed immedi‐
ately so that they are air-tight.
which the refrigerant oil is supplied. This date is not relevant if
the bottle is sealed air-tight. If the bottle is sealed air-tight, the
refrigerant oil can also be used after the date stated on the
bottle.
♦ PAG oil becomes unusable if it is stored in open containers for
a long period of time.
♦ Approved refrigerant oils ⇒ page 319

♦ Refrigerant oil capacities ⇒ page 321

10.2.1 Approved refrigerant oils
Note
♦ The oils used with refrigerant R12 are not suitable for refrig‐
erant R134a.
♦ The name of the compressor manufacturer “Nippondenso”
has been changed to “Denso”.
♦ The special refrigerant oils to be used exclusively for refriger‐
ant circuits with refrigerant R134a are not always commercial‐
ly available.
♦ Refrigerant oils intended specifically for a particular air condi‐
tioner compressor can therefore be obtained from the replace‐
ment parts range ⇒ Electronic parts catalogue .
the refrigerant circuit must be flushed
R134a”, page 88 .
♦ Using other refrigerant oils may cause the system to fail, as it
cannot be guaranteed that they will mix and circulate with re‐
frigerant R134a to lubricate the air conditioner compressor.
♦ There are different refrigerant oils for “Zexel/Valeo”, “Denso”,
“Delphi/Mahle” and “Sanden” compressors. ⇒ Electronic parts
catalogue.
♦ The refrigerant oil (part no. G 052 300 A2; external designation
ND 8) for use in refrigerant circuits with “Denso” (formerly
“Nippondenso”) air conditioner compressors is also included
in the retrofit kit (part no. 4A0 298 107 A). It is the same for
mechanically and electrically driven air conditioner compres‐
sors ⇒ Electronic parts catalogue .
♦ For refrigerant circuits with “Zexel/Valeo” air conditioner com‐
pressors, use refrigerant oil with part no. G 052 154 A2 ⇒
♦ For refrigerant circuits with mechanically driven “Sanden” air
conditioner compressors, use refrigerant oil with part no. G
052 154 A2 (or part no. G 052 535 M2) ⇒ Electronic parts
catalogue .
♦ For mechanically driven “Sanden” air conditioner compres‐
sors, refrigerant oil with part no. G 052 535 M2 (external
designation SP A2) can be used instead of refrigerant oil with
part no. G 052 154 A2 (external designation SP 10) ⇒ Elec‐
♦ For refrigerant circuits with electrically driven “Visteon” or
“Sanden” air conditioner compressors (e.g. in the Audi A3 e-
tron and Audi Q7 e-tron), use refrigerant oil with part no. G 052
535 M2 ⇒ Electronic parts catalogue .
♦ For refrigerant circuits with “Delphi/Mahle” compressor, you
can use refrigerant oil with part no. G 052 154 A2 or refrigerant
oil with part no. G 052 300 A2 ⇒ Electronic parts catalogue .
♦ For refrigerant circuits with “Zexel / Valeo” air conditioner com‐

pressors, use can be made of both the refrigerant oil (G 052
154 A2) and the refrigerant oil (G 052 200 A2) contained in the
retrofit kit (part no. 4A0 298 107) ⇒ Electronic parts catalogue .
♦ At present, the electrically driven air conditioner compressor
(e.g. of “Denso” type on the Audi Q5 Hybrid) is filled with the
same refrigerant oil as the mechanically driven air conditioner
compressor of the same manufacturer (refer to rating plate on
air conditioner compressor) ⇒ Electronic parts catalogue .
♦ To ensure that air conditioner service stations do not always
need to be cleaned before starting work on a different type of
vehicle (due to the different refrigerant oils used depending on
the manufacturer of the air conditioner compressor), specified
small quantities (up to max. 10%) of the total quantity of re‐
frigerant oil in the corresponding refrigerant circuit are permit‐
ted to meet a different specification from that of the air
conditioner compressor installed. On Audi vehicles, this
means that it is permitted to use max. 10% refrigerant oil of
the type SP 10 (or SP A2) on vehicles with a “Denso” air con‐
ditioner compressor (with ND 8 refrigerant oil) or max. 10%
refrigerant oil of the type ND 8 on vehicles with a “Sanden”,
“Delphi/Mahle” or “Visteon” air conditioner compressor (with
SP 10 or SP A2 refrigerant oil). However, other refrigerant oils
not listed here must not be used (different properties due to
different viscosity, different/missing additives etc.).
♦ Instead of using an air conditioner service station, refrigerant
oil extracted when emptying the refrigerant circuit can be add‐
ed via an open connection or, when valve -3- is removed, via
a service connection -1- or -2- using a commercially available
disposable syringe
⇒ “3.5 Connections for quick-release coupling in refrigerant
circuit”, page 41 before evacuating the refrigerant circuit. This
may be practical e.g. if the refrigerant oil specified for the re‐
frigerant circuit is normally only rarely used. The refrigerant oil
added must always be fresh ⇒ “2.6 Refrigerant oil”, page 12
and ⇒ Electronic parts catalogue . The positioning of service
connection -1- or -2- in the vehicle is different ⇒ Heating, air
conditioning (vehicle-specific Workshop Manual).
Important information:
As refrigerant oil is extremely hygroscopic, open containers must
be closed and re-sealed immediately after use to prevent mois‐
ture from entering.
Note

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

10.2.2 Refrigerant oil capacities
Note
♦ For the assignment of the air conditioner compressor (“Zexel/

Valeo”, “Sanden” or “Denso”), refer to the vehicle-specific
Workshop Manual ⇒ Heating, air conditioning; Rep. gr. 87 ;
♦ With “Zexel / Valeo”, “Denso” and “Sanden” compressors, the
amount of refrigerant oil in the replacement compressor cor‐
responds to the total quantity of oil to be added. When renew‐
ing the air conditioner compressor, the quantity of refrigerant
oil in the compressor to be fitted must therefore be adjusted
(an incorrect refrigerant oil quantity will cause damage to the
compressor).
♦ When pouring (flushing) the refrigerant oil out of the replace‐
ment compressor (or the defective air conditioner compres‐
sor), a small quantity of oil generally remains in the
mechanically driven air conditioner compressor (20 to 30
cm3). This refrigerant oil does not affect the function of the air
conditioner and can therefore be ignored (always remains in
the compressor). A larger quantity of refrigerant oil may remain
in the electrically driven air conditioner compressor depending
on the structure and version, which may mean that the air
conditioner compressor may need to be flushed to empty it
♦ On initial switch-on, the refrigerant oil is distributed throughout
♦ Unless otherwise stated, the refrigerant oil capacities specified
also apply to the corresponding “S” and “RS” versions of this
vehicle model.
♦ For refrigerant oil quantities required for topping up when re‐
newing defective refrigerant circuit components, refer to
⇒ page 258 . Also ⇒ Heating, air conditioning; Rep. gr. 87 ;
♦ ⇒ “10.2.3 Capacities for Audi A1 (8X_) 2011 ►”, page 322

♦ ⇒ “10.2.4 Capacities for Audi A2 (8Z_) 2001 ►”, page 325
♦ ⇒ “10.2.5 Capacities for Audi A3 (8L_) 1997 ► and Audi TT
(8N_) 1999 ►”, page 325
♦ ⇒ “10.2.6 Capacities for Audi A3 (8P_) 2004 ►, Audi Q3 (8U_
or 84_ for China) 2012 ►”, page 326
♦ ⇒ “10.2.7 Capacities for Audi Q2 (GA_) 2017 ►, Audi A3 (8V_
RS 3 (8V_) 2016 ►”, page 328
♦ ⇒ “10.2.8 Capacities for Audi TT (8J_) 2007 ►”, page 330
♦ ⇒ “10.2.9 Capacities for Audi TT (FV_) 2015 ►”, page 332
♦ ⇒ “10.2.10 Capacities for Audi 80 (8A_/8C_), Audi Coupé
(8B_), Audi Cabriolet (8G_) ► 2002”, page 333
♦ ⇒ “10.2.12 Capacities for Audi A4 (8E_) 2001 ►, Audi A4 Cab‐

riolet (8H_) 2003 ►”, page 334
♦ ⇒ “10.2.13 Capacities for Audi A4 (8K_) 2008 ►, Audi A5
(8R_) 2011 ►”, page 336
♦ ⇒ “10.2.14 Capacities for Audi A4 (8W_) 2016 ►, Audi A4 (86_
for China) 2017 ►, Audi A5 (F5_) 2016 ►, Audi Q5 (FY_) 2017
►, Audi Q5 (87_ for China) 2019 ► ”, page 343
♦ ⇒ “10.2.15 Capacities for Audi 100/Audi A6 (4A_) ► 1998”,
page 343
♦ ⇒ “10.2.16 Capacities for Audi A6 (4B_) 1998 ► and Audi all‐
road ► 2005”, page 344
♦ ⇒ “10.2.17 Capacities for Audi A6 (4F_) 2005 ►”, page 346
♦ ⇒ “10.2.18 Capacities for Audi A6 (4G_ or 4X_ for China ) 2011
►, Audi A7 (4G_ or 4X_ for China) 2011 ►, Audi A6 hybrid (4G_)
2012 ►, A6 e-tron (4G_) 2017 ►”, page 347
♦ ⇒ “10.2.19 Capacities for Audi V8 (4C_) ► 1994”, page 350
♦ ⇒ “10.2.21 Capacities for Audi A8 (4E_) 2003 ►”, page 351
♦ ⇒ “10.2.22 Capacities for Audi A8 (4H_) 2010 ►, Audi A8 hybrid
(4H_) 2012 ►”, page 352
♦ ⇒ “10.2.23 Capacities for Audi Q7 (4L_) 2006 ►”, page 356
♦ ⇒ “10.2.24 Capacities for Audi Q7 (4M_) 2016 ►”, page 358
♦ ⇒ “10.2.25 Capacities for Audi R8 (42_) 2008 ►, Audi R8 (4S_)
2015 ►”, page 358
10.2.3 Capacities for Audi A1 (8X_) 2011 ►

• Expansion valve
• Receiver
• Air conditioner compressor from various manufacturers with
air conditioner compressor regulating valve - N280- (without
magnetic clutch) ⇒ Heating, air conditioning; Rep. gr. 87 ;
Vehicle Production Total quantity of oil in re‐ Quantity of refrigerant oil Differing characteristics of
model period frigerant circuit in cm3 in replacement compres‐ this refrigerant circuit
sor in cm3
Audi A1 From 08.10 110 +/- 10 110 +/- 10 • Air conditioner com‐
onwards pressor manufactured
by “Sanden” (or “Del‐
phi/Mahle”), part num‐
ber “5N0 xxx xxx”
90 +/- 10 90 +/- 10 Air conditioner compres‐

sor manufactured by
“Denso”, part number
“1K0 xxx xxx”
110+ / - 10 110 +/- 10 Air conditioner compres‐
sor manufactured by
“Denso”, part number
“5Q0 xxx xxx” (see notes)

sor in cm3
75+ / - 10 75+ / - 10 “Sanden” air conditioner
compressor, part number
“5K0 xxx xxx”
From 07.12 75+ / - 10 75+ / - 10 Air conditioner compres‐
onwards sor manufactured by “San‐
den”, part number “5Q0
xxx xxx”
110 +/- 10 110 +/- 10 • Air conditioner com‐
pressor manufactured
by “Delphi/Mahle”, part
number “5K0 xxx xxx”
or “5Q0 xxx xxx”
Note
♦ The replacement compressor contains the full quantity of oil

intended for the refrigerant circuit. If the air conditioner com‐
pressor is renewed, the quantity of oil in the compressor must
therefore be adjusted accordingly ⇒ page 258 .
the production period and engine.
♦ At the start of production, “Denso” air conditioner compressors
(type “6 SEU 14C”) or “Sanden” air conditioner compressors
(“7 PXE 16/14”) were fitted; see ⇒ Electronic parts catalogue
♦ Depending on the engine, “Sanden” air conditioner compres‐
sors (type “11 PXC 14”) or “Delphi/Mahle” air conditioner
compressors (type “6 CVC 140”) may also be fitted at a later
date (introduction not yet finalised, planned from 09.12 on‐
wards); see ⇒ Electronic parts catalogue and ⇒ Heating, air
Workshop Manual).
♦ At a later date, air conditioner compressors manufactured by
“Denso” or “Sanden” in another version may be installed de‐
pending on the engine (introduction not yet finalised) ⇒ Elec‐
♦ These air conditioner compressors are available as replace‐
ment parts with different oil capacities, so it is important to pay
attention to the oil quantity in the air conditioner compressor
and to check the exact part number ⇒ Heating, air condition‐
♦ The different oil quantities in the air conditioner compressor
may result from the design of the air conditioner compressor
(with or without oil separator at high-pressure connection) or,
in the case of identical air conditioner compressors, from the
design of the refrigerant circuit; pay attention to these quanti‐
ties. Too much oil in the circuit results in higher pressures and
a reduced cooling output of the system. Too little oil may lead
to lubrication problems in the air conditioner compressor.
♦ The air conditioner compressor may have been fitted at the
factory with a type plate indicating the part number and the
quantity of refrigerant oil in the air conditioner compressor.
conditioner compressor with part number “5Q0 xxx xxx” was
gradually increased from 80 ccm to 110 ccm. The increased
quantity of refrigerant oil applies retroactively to all vehicles
with this air conditioner compressor. On vehicles manufac‐
tured with this air conditioner compressor up to 11.2012, check
whether the quantity of refrigerant oil has already been in‐
creased during a previous workshop visit. If not, add 30 ccm
of refrigerant oil to the refrigerant circuit . Then enter the re‐
frigerant oil capacity on the label in waterproof ink ⇒ Heating,
air conditioning; Rep. gr. 87 ; Installation location overview -
Air conditioning (vehicle-specific Workshop Manual) and fill
the refrigerant circuit with the quantity of refrigerant indicated
above
⇒ “10.1.1 Capacities for Audi A1 (8X_) 2011 ►”, page 277 .

10.2.4 Capacities for Audi A2 (8Z_) 2001 ►

• Restrictor
• Reservoir
• Air conditioner compressor with air conditioner compressor
regulating valve - N280- (no magnetic clutch)
• “Denso” air conditioner compressor ⇒ Heating, air condition‐
shop Manual) and ⇒ Electronic parts catalogue
Vehicle model Production period Total quantity of oil in refrig‐ Quantity of refrigerant oil in replace‐
erant circuit in cm3 ment compressor in cm3
Audi A2 From 06.00 onwards 180 +/-15 180+/-15
Note

♦ As the air conditioner compressor always runs together with
the engine and the entire quantity of refrigerant oil is contained
in the air conditioner compressor, the circuit must be assem‐
bled completely before the engine is started ⇒ Heating, air
Workshop Manual).
♦ As replacement air conditioner compressors of this type with
different oil capacities are available, observe the exact part
number. ⇒ Electronic parts catalogue.
10.2.5 Capacities for Audi A3 (8L_) 1997 ► and Audi TT (8N_) 1999 ►
• Expansion valve
• Receiver
• “Sanden” or “Zexel/Valeo” air conditioner compressor ⇒ Heat‐
Vehicle mod‐ Production period Total quantity of oil in refrig‐ Quantity of refrigerant oil in replace‐
el erant circuit in cm3 ment compressor in cm3
Audi A3 From 08.96 135 +/-15 135+/-15
Audi TT From 10.98 135 +/-15 135+/-15
Note

parts catalogue .
10.2.6 Capacities for Audi A3 (8P_) 2004 ►,

Audi Q3 (8U_ or 84_ for China) 2012 ►
Note
♦ The refrigerant capacities in the following table apply to the

Audi A3, Audi A3 Sportback, Audi RS 3, Audi A3 Cabriolet and
Audi Q3 (and RS Q3).
♦ On certain versions for China the type designation 84_ is used
instead of 8U_.

• Expansion valve
• Receiver
sor in cm3
Audi A3 From 05.03 180 +/- 10 180 +/- 10 • “Denso” air conditioner
Audi Q3 to 10.03 compressor of “7 SEU
16” type
From 10.03 120 +/- 10 120 +/- 10 • “Zexel / Valeo” air con‐
onwards ditioner compressor
110 +/- 10 110 +/- 10 Air conditioner compres‐

sor manufactured by “San‐
den”, except part number
“5K0 xxx xxx”
140 +/- 10 140 +/- 10 “Denso” air conditioner
compressor of “7 SEU 17”
type

sor in cm3
From 06.07 90 +/- 10 90 +/- 10 • “Denso” air conditioner
onwards compressor of “6 SEU
14” type
From 08.07 110 +/- 10 110 +/- 10 • “Delphi/Mahle” air con‐

onwards ditioner compressor
From 06.13 75+ / - 10 75+ / - 10 “Sanden” air conditioner

onwards compressor, part number
“5K0 xxx xxx”
Note

ditioner compressors of type “7 SEU 16” from “Denso” (e.g. air
conditioner compressor with part no. 1K0 820 803 up to index
“D”). In Model Year 2004 (as of approx. 10.03), a gradual
change was made to a different type of “Denso” compressor
(“7 SEU 17” e.g. air conditioner compressor with part no. 1K0
820 803 as of index “E”).
♦ With effect from Model Year 2004 (as of approx. 10.03), “Zex‐
el / Valeo” (type “DSC17E”) and “Sanden” (type “PXE16”) air
conditioner compressors are also gradually being introduced
depending on the engine ⇒ Electronic parts catalogue .
♦ From model year 2008 onwards, “Denso” compressors (type
“6 SEU 14”) and “Delphi/Mahle” air conditioner compressors
are also gradually being introduced depending on the engine
⇒ Electronic parts catalogue and ⇒ Heating, air conditioning;
Manual).
♦ This air conditioner compressor is available as a replacement
part with different oil capacities, so it is important to pay at‐
tention to the oil quantity in the compressor and to check the
exact part number ⇒ Heating, air conditioning; Rep. gr. 87 ;
10.2.7 Capacities for Audi Q2 (GA_) 2017 ►,

Audi A3 (8V_ or 85_ for China) 2013 ►,
Audi A3 e-tron (8V_ ) 2015 ►, Audi RS 3
(8V_) 2016 ►
Note
The capacities for the Audi A3 (8V_ or 85_ for China) apply to all
versions (Saloon, Sportback, Cabriolet, etc.)

• Expansion valve
• Receiver
parts catalogue (all vehicles except Audi A3 e-tron)
• On vehicles with high-voltage system (Audi A3 e-tron): elec‐
trically driven “Sanden” or “Visteon” air conditioner compres‐
sors ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
parts catalogue
Note
Various mechanically driven air conditioner compressors are fit‐

ted depending on the production period and the engine (these
compressors do not have a magnetic clutch) ⇒ Heating, air con‐
shop Manual).
sor in cm3
Audi Q2 From 07.16 110 +/- 10 110 +/- 10 • “Denso” air conditioner
Audi A3 onwards compressor
From 05.12
onwards
75+ / - 10 75 +/- 10 • “Sanden” air condition‐
er compressor
110 +/- 10 110 +/- 10 • “Delphi/Mahle” air con‐

ditioner compressor
Audi A3 From 09.14 120 +/- 10 120 +/- 10 • Electrically driven air
e-tron onwards conditioner compres‐
sor
• With second evapora‐
tor in high-voltage bat‐
tery heat exchanger
• Different type of refrig‐
erant oil

sor in cm3
Audi From 02.15 110 +/- 10 110 +/- 10 • “Sanden” air condition‐
RS 3 onwards er compressor with
• With double-belt pulley and
5-cyl. different type of con‐
en‐ denser fitted ⇒ Elec‐
gine tronic parts catalogue
and ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ;
Refrigerant circuit (ve‐
hicle-specific Work‐
shop Manual).
Note

♦ The reason for the different oil quantities in the air conditioner
compressor may be the design of the air conditioner compres‐
sor, or the design of the refrigerant circuit on vehicles with an
identical air conditioner compressor; please note the different
oil quantities. Too much oil in the circuit results in higher pres‐
sures and a reduced cooling output of the system. Too little oil
may lead to lubrication problems in the air conditioner com‐
pressor.
conditioner compressor was gradually increased from 80 ccm
to 110 ccm. The increased quantity of refrigerant oil applies
retroactively to all vehicles with this make of air conditioner
compressor. On vehicles manufactured up to 06.2013, check
whether the quantity of refrigerant oil has already been in‐
creased during a previous workshop visit. If not, add 30 ccm
of refrigerant oil to the refrigerant circuit . Then enter the re‐
frigerant oil capacity on the label with a waterproof pen ⇒
hicle-specific Workshop Manual), and fill the refrigerant circuit
with the quantity of refrigerant indicated above
⇒ “10.1.5 Capacities for Audi Q2 (GA_) 2017 ►, Audi A3 (8V_
RS 3 (8V_) 2016 ►”, page 283 .
♦ The refrigerant oil used in the Audi A3 e-tron must be different
to the oil used in vehicles with a mechanically driven air con‐
ditioner compressor (e.g. refrigerant oil with the part number
G 052 535 M2) ⇒ Electronic parts catalogue . Since the stor‐
age tanks in most air conditioner service stations do not con‐
tain this refrigerant, the refrigerant oil extracted when empty‐
ing the refrigerant circuit cannot be refilled from the air
conditioner service station. On these vehicles, refrigerant oil
can be refilled via a service connection e.g. before evacuating
the refrigerant circuit via an open connection or with valve re‐
moved ⇒ page 319 .
♦ For refrigerant circuits with electrically driven “Visteon” or
“Sanden” air conditioner compressors (e.g. in the Audi A3 e-
tron), use refrigerant oil with part no. G 052 535 M2 ⇒
10.2.8 Capacities for Audi TT (8J_) 2007 ►


• Expansion valve
• Receiver
sor in cm3
Audi TT From 08.06 90 +/- 10 90 +/- 10 • “Denso” air conditioner
onwards compressor of “6 SEU
14” type
110 +/- 10 110 +/- 10 • “Sanden” air condition‐

er compressor

ditioner compressor
Note
♦ The replacement air conditioner compressor contains the full

quantity of oil intended for the refrigerant circuit. If the air con‐
ditioner compressor is renewed, the quantity of oil in the
compressor must therefore be adjusted accordingly
⇒ page 258 .
ditioner compressors of type “6 SEU 14” manufactured by
“Denso”. This air conditioner compressor has no magnetic
clutch (it is constantly driven by the engine). Air conditioner
♦ From model year 2008 onwards, “Sanden” air conditioner
compressors (type “PXE16”) are gradually being introduced
for certain engines; these air conditioner compressors do not
engine) ⇒ Electronic parts catalogue and ⇒ Heating, air con‐
Workshop Manual).
♦ From model year 2011 onwards, “Delphi/Mahle” air condition‐
er compressors are also gradually being introduced depend‐
ing on the engine ⇒ Electronic parts catalogue and ⇒ Heating,
10.2.9 Capacities for Audi TT (FV_) 2015 ►

• Expansion valve
• Receiver
parts catalogue

Note
Various mechanically driven air conditioner compressors are fit‐

ted depending on the production period and the engine (these
compressors do not have a magnetic clutch) ⇒ Heating, air con‐
shop Manual).
sor in cm3
Audi TT From 10.14 110 +/- 10 110 +/- 10 • “Denso” air conditioner
onwards compressor
75+ / - 10 75 +/- 10 • “Sanden” air condition‐

er compressor

ditioner compressor
TT RS From 07.16 110 +/- 10 110 +/- 10 • “Denso” air conditioner

• With onwards compressor
5-cyl.
en‐
gine
Note

♦ The reason for the different oil quantities in the air conditioner
compressor may be the design of the air conditioner compres‐
sor, or the design of the refrigerant circuit on vehicles with an
identical air conditioner compressor; please note the different
oil quantities. Too much oil in the circuit results in higher pres‐
sures and a reduced cooling output of the system. Too little oil
may lead to lubrication problems in the air conditioner com‐
pressor.
10.2.10 Capacities for Audi 80 (8A_/8C_), Audi Coupé (8B_), Audi Cabriolet (8G_)
► 2002
• Reservoir
Audi 80 From 10.92 250 + 50 250 + 50
Audi Coupé
Audi Cabrio‐
let
Note

intended for the circuit. If the air conditioner compressor is re‐
newed, the quantity of oil in the compressor must therefore be
adjusted accordingly ⇒ page 258 .

• Restrictor
• Reservoir
Audi A4 From 11.94 250 + 50 250 + 50
Note

depending on the engine and production period ⇒ Heating, air
10.2.12 Capacities for Audi A4 (8E_) 2001 ►, Audi A4 Cabriolet (8H_) 2003 ►

• Restrictor
• Reservoir
pressor regulating valve - N280- (without magnetic clutch) ⇒
hicle-specific Workshop Manual) and ⇒ Electronic parts cata‐
logue
sor in cm3
Audi RS 4 to 01.04 pressor type “6 SEU
• All vehi‐ 12” “6 SEU 14” “7 SEU
cles: 16” or “7 SEU 17” (refer
to notes below)
From 01.04 120 +/- 10 120 +/- 10 • Air conditioner com‐

onwards pressor type “6 SEU
• All except 14” or “7 SEU 17” (refer
8-cyl. en‐ to notes below)
gine
From 01.04 130 +/- 10 130 +/- 10 • Air conditioner com‐

onwards pressor type “7 SEU
• 8-cyl. en‐ 17” (refer to notes be‐
gine only low)
Note

depending on the engine and production period. This air con‐
ditioner compressor is available as a replacement part with
different oil capacities, so it is important to pay attention to the
♦ At the start of production, the compressor types in the first line
of the table were supplied with a refrigerant oil quantity of 180
cm 3. These air conditioner compressors can be recognised
from the index of the part number (8E0 260 805 with one index
or with double index up to “AH”). In model year 2004 (as of
approx. 01.04), a gradual change was made to other types of
compressor with a refrigerant oil quantity of 120 cm 3 or 130
cm 3. These air conditioner compressors can be recognised
from the index of the part number 8E0 260 805 (with double
index as of “AJ”) or 4F0 260 805 (and index “E” for vehicles
with 8-cyl. engine) ⇒ Electronic parts catalogue .
10.2.13 Capacities for Audi A4 (8K_) 2008 ►,

Audi A5 Coupé and Sportback (8T_)
2008 ►, Audi Q5 (8R_ or 83_ for China)
2008 ►, Audi A5 Cabriolet (8F_) 2009 ►,
Audi Q5 hybrid (8R_) 2011 ►
Note
♦ Also applies for the Audi RS 4, Audi S5, Audi SQ5 and Audi
RS 5.
♦ Different capacities depending on version and production pe‐
riod (see the following tables)
♦ On certain Audi Q5 versions for China the type designation
83_ is used instead of 8R_.

• Expansion valve
• Receiver

• Refrigerant pipe with internal heat exchanger.

air conditioning system magnetic clutch - N25- , depending on
engine and production period) ⇒ Heating, air conditioning;
Manual) and ⇒ Electronic parts catalogue (all vehicles except
Audi Q5 hybrid)
• On vehicles with a high-voltage system (Audi Q5 hybrid): elec‐
♦ Capacity for Audi A4, Audi A5 and Audi A5 Cabriolet
⇒ page 337
♦ Capacity for Audi Q5 and Audi Q5 hybrid ⇒ page 339
♦ Capacity for Audi RS 4, Audi RS 5 ⇒ page 341
♦ General notes on quantity of refrigerant oil and refrigerant cir‐
cuit ⇒ page 342
Audi A4, Audi A5 and Audi A5 Cabriolet
Note
♦ Also applies to the Audi S5.

♦ Capacity for Audi RS 5 Cabriolet ⇒ page 341
Ve‐ Produc‐ Total quantity Quantity of re‐ Differing char‐

hicle tion peri‐ of oil in refrig‐ frigerant oil in acteristics of
mod od erant circuit in replacement this refrigerant
el cm3 compressor in circuit
cm3
Audi ♦ Audi 150 +/- 10 150 +/- 10 • Air conditioner
A4 A4, compressor
Audi from manufactured
A5 10.07 by “Denso”,
(Co to type
upé, 03.12 “6 SEU 14” and
Cab “7 SEU 17” (air
rio‐ ♦ Audi conditioner
let A5 compressor
and Coupé with part num‐
Spo and ber
rtba Sport‐ 8K0 xxx xxx)
ck) back,
from
05.07
to
03.12
♦ Audi
A5
Cab‐
riolet,
from
03.09
to
03.12
Ve‐ Produc‐ Total quantity Quantity of re‐ Differing char‐

hicle tion peri‐ of oil in refrig‐ frigerant oil in acteristics of
mod od erant circuit in replacement this refrigerant
cm3
♦ Audi 110 +/- 10 110 +/- 10 • Air condi‐
A4, tioner com‐
from pressor
08.11 manufac‐
to tured by
03.12 “Denso”,
(with type
a cer‐ “6 SAS 14”
tain with mag‐
en‐ netic clutch
gine; (air condi‐
see tioner com‐
notes) pressor with
part number
8T0 xxx xxx)
♦ All ve‐ 110 +/- 10 110 +/- 10 • Air condi‐

hicles tioner com‐
from pressor
03.12 manufac‐
on‐ tured by
wards “Denso”,
(see type
notes) “6 SES 14”
without
magnetic
clutch, or
type
“6 SAS 14”
with mag‐
netic clutch
(air condi‐
tioner com‐
pressor with
part number
8T0 xxx xxx)

Note
♦ Starting with the product changeover in March 2012, Audi A4

and Audi A5 vehicles (except RS models) are no longer avail‐
able with 8-cyl. engines.
♦ From March 2012 onwards, the refrigerant circuit (air condi‐
tioner compressor, condenser, evaporator etc.) was gradually
changed (indicated on label for refrigerant circuit) ⇒ Heating,
♦ From August 2011 onwards, air conditioner compressors with
air conditioning system magnetic clutch - N25- were gradually
catalogue .
lettering on condenser)
⇒ “10.1.11 Capacities for Audi A4 (8K_) 2008 ►, Audi A5
(8R_) 2011 ►”, page 291 and ⇒ Electronic parts catalogue .
Audi Q5 and Audi Q5 hybrid
Note
Also applies for the Audi SQ5.
Ve‐ Pro‐ Total quantity Quantity of re‐ Differing char‐

hicle duction of oil in refrig‐ frigerant oil in acteristics of
mod period erant circuit in replacement this refrigerant
cm3
Audi From 150 +/- 10 150 +/- 10 • Air conditioner
Q5 09.08 compressor
to manufactured
06.12 / by “Denso”,
08.12 type
(gradu‐ “6 SEU 14” (air
al conditioner
change compressor
-over; with part num‐
see ber
notes) 8K0 xxx xxx)

cm3
From 110 +/- 10 110 +/- 10 • Air condi‐
08.11 tioner com‐
to pressor
06.12 / manufac‐
08.12 tured by
(with a “Denso”,
certain type
engine, “6 SAS 14”
gradual with mag‐
conver‐ netic clutch
sion; (air condi‐
see tioner com‐
notes) pressor with
part number
8T0 xxx xxx)
From 110 +/- 10 110 +/- 10 • Air condi‐

06.12 / tioner com‐
08.12 pressor
on‐ manufac‐
wards tured by
(gradu‐ “Denso”,
al con‐ type
ver‐ “6 SES 14”
sion; without
see magnetic
notes) clutch, or
type
“6 SAS 14”
with mag‐
netic clutch
(air condi‐
tioner com‐
pressor with
part number
8T0 xxx xxx)
Audi From 200 +/- 20 200 +/- 20 • Electrically

Q5 05.11 driven air
hy‐ on‐ conditioner
brid wards compres‐
sor manu‐
factured by
“Denso”

Note
♦ Between June and August 2012, the refrigerant circuit (air

conditioner compressor, condenser, evaporator etc.) was
gradually converted (depending on the engine and the vehicle
version). This means that the refrigerant and refrigerant oil
capacity for these vehicles has also changed (indicated on la‐
bel for refrigerant circuit) ⇒ page 291 , ⇒ Heating, air condi‐
♦ On the Audi Q5 hybrid there is no conversion of the refrigerant
circuit in model year 2012 (see other versions).
♦ From August 2011 onwards, air conditioner compressors with
air conditioning system magnetic clutch - N25- were gradually
catalogue .
lettering on condenser)
⇒ “10.1.11 Capacities for Audi A4 (8K_) 2008 ►, Audi A5
(8R_) 2011 ►”, page 291 and ⇒ Electronic parts catalogue .
♦ At the start of production, the Audi Q5 hybrid is fitted with an
♦ At the start of production, the Audi Q5 hybrid was fitted with
an air conditioner compressor with a refrigerant oil quantity of
oil quantity was increased to 200 ccm. The refrigerant oil does
not have to be topped up on vehicles fitted with an air condi‐
tioner compressor with a refrigerant oil quantity of 160 ccm.
However, if the refrigerant circuit has been cleaned (flushed)
for example, a total of 200 ccm should also be filled in this
vehicle as the specified refrigerant oil quantity. The correct
amount of refrigerant oil will already be filled into a replace‐
ment air conditioner compressor ⇒ Electronic parts cata‐
logue .
Audi RS 4, Audi RS 5
Note
Also applies for the Audi RS 5 Cabriolet.
sor in cm3
Audi RS ♦ RS 4 from 150 + /- 10 150 +/- 10 • “Denso” air conditioner
4 and 04.12 on‐ compressor “7 SEU 17”
RS 5 wards
♦ RS 5 from
03.10 on‐
wards
Note
♦ On the Audi RS 4 and RS 5 there is no changeover of the

refrigerant circuit in model year 2012 (see other versions).
Further notes
Note

were manufactured by “Denso” (type “6 SEU 14” for vehicles
with 4-cyl. and 6-cyl. engine and type “7 SEU 17” for vehicles
with 8-cyl. engine); these air conditioner compressors do not
engine). In model year 2012, the air conditioner compressor
type “6 SEU 14” is gradually being replaced by type
“6 SES 14”. Air conditioner compressors produced by other
manufacturers may also be fitted at a later date (depending on
the engine) ⇒ Electronic parts catalogue and ⇒ Heating, air
Workshop Manual).
♦ On the Audi Q5 hybrid, an electrically driven air conditioner
compressor with integrated control electronics is installed.
parts catalogue .
♦ These air conditioner compressors are available as replace‐
ment parts with different oil capacities, so it is important to pay
attention to the oil quantity in the air conditioner compressor
and to check the exact part number ⇒ Heating, air condition‐
♦ At the start of production, air conditioner compressors with air
conditioning system magnetic clutch - N25- and with part num‐
ber 8T0 260 805 with index “C” were installed. The label on
these air conditioner compressors indicates a refrigerant oil
capacity of 80 +/- 10 cm3. Shortly after the start of production,
the refrigerant oil quantity was raised also to 110 +/- 10 cm3
for this air conditioner compressor.

10.2.14 Capacities for Audi A4 (8W_) 2016 ►,

Audi A4 (86_ for China) 2017 ►, Audi A5
(F5_) 2016 ►, Audi Q5 (FY_) 2017 ►,
Audi Q5 (87_ for China) 2019 ►
Note
Also applies for Audi A4 allroad, Audi A4 (86_ for China), Audi A5
(all versions) etc.

• Expansion valve
• Receiver
N280- , with or without air conditioning system magnetic clutch
- N25- (depending on engine) ⇒ Heating, air conditioning;
cm3
Audi From 110 + /- 10 110 +/- 10 • “Denso” air
A4 07.15 conditioner
Audi on‐ compres‐
A5 wards sor
Audi
Q5
100 + /- 10 100 +/- 10 • “Sanden”
air condi‐
tioner com‐
pressor
Note

♦ Different refrigerant oils depending on air conditioner com‐
pressor manufacturer ⇒ page 319 and ⇒ Electronic parts
catalogue .
10.2.15 Capacities for Audi 100/Audi A6 (4A_) ► 1998

• Restrictor
• Reservoir

Audi 100 / From 10.92 250 + 50 250 + 50
Audi A6 to 03.97
Note

♦ The Audi 100 / Audi A6 features different air conditioner com‐
pressors depending on the engine and production period.
Exclusive use was made at the start of production of “Zexel /
onwards, “Denso” air conditioner compressors were gradually
introduced for vehicles with 6-cylinder engines ⇒ Heating, air
10.2.16 Capacities for Audi A6 (4B_) 1998 ► and Audi allroad ► 2005
• Restrictor
• Reservoir
• “Denso” or “Zexel/Valeo” air conditioner compressor with air
conditioning system magnetic clutch - N25- ⇒ Heating, air
Vehicle model Production peri‐ Total quantity of oil Quantity of refrigerant Differing characteris‐
od in refrigerant cir‐ oil in replacement com‐ tics of this refrigerant
cuit in cm3 pressor in cm3 circuit
Audi A6/Audi all‐ From 04.97 on‐ 250 + 50 250 + 50 • Refer to notes be‐
road wards low.
• 4-cyl. petrol en‐ All
gine except 2.0
ltr.
• 6-cyl. petrol en‐
gine except 3.0
ltr.
Audi A6/Audi all‐ From 04.97 250 + 50 250 + 50 • Refer to notes be‐
road to 05.01 low.
• 4-cyl. diesel en‐
gine
gine
(see notes for Audi
allroad)

Vehicle model Production peri‐ Total quantity of oil Quantity of refrigerant Differing characteris‐
od in refrigerant cir‐ oil in replacement com‐ tics of this refrigerant
cuit in cm3 pressor in cm3 circuit
Audi A6 From 04.97 on‐ 250 + 50 250 + 50 • Refer to notes be‐
• 8-cyl. engine wards low.
(with camshaft All
drive via toothed
belt)
Note

♦ As of Model Year 2002, the Audi A6 features air conditioner
compressors with a magnetic clutch or regulating valve (dif‐
ferent oil quantities) depending on the engine. This change
was gradually introduced for the Audi allroad with 6-cyl. diesel
engine in model year 2003 ⇒ Heating, air conditioning; Rep.

• Restrictor
• Reservoir
•
Vehicle model Production peri‐ Total quantity of oil Quantity of refrig‐ Differing characteristics of
od in refrigerant cir‐ erant oil in re‐ this refrigerant circuit
cuit in cm3 placement com‐
pressor in cm3
Audi A6 All 220 + 20 220 + 20 Air conditioner compressor
• 4-cyl. 2.0 ltr. pet‐ type “6 SEU 12” or “7 SEU
rol engine 16” (refer to notes below)
• 6-cyl. 3.0 ltr. pet‐
rol engine
Audi A6/Audi allroad From 05.01 on‐ 245 + 20 245 + 20 Air conditioner compressor
• 4-cyl. diesel en‐ wards type “6 SEU 12” or “7 SEU
gine 16” (refer to notes below)
gine
(see notes for Audi
allroad)
Vehicle model Production peri‐ Total quantity of oil Quantity of refrig‐ Differing characteristics of
od in refrigerant cir‐ erant oil in re‐ this refrigerant circuit
cuit in cm3 placement com‐
pressor in cm3
Audi allroad All 220 + 20 220 + 20 Air conditioner compressor
• 8-cyl. engine type “7 SEU 17” (refer to
(with camshaft notes below)
drive via chain)
Note

♦ As of Model Year 2002, the Audi A6 features air conditioner
compressors with a magnetic clutch or regulating valve (dif‐
ferent oil quantities) depending on the engine. This change
was gradually introduced for the Audi allroad with 6-cyl. diesel
engine in model year 2003.
♦ The air conditioner compressor with air conditioner compres‐
sor regulating valve - N280- is available as a replacement part
with different oil capacities, so it is important to pay attention
to the exact part number ⇒ Heating, air conditioning; Rep. gr.
10.2.17 Capacities for Audi A6 (4F_) 2005 ►
Note
Also applies to the Audi S6 and Audi RS 6.

• Restrictor
• Reservoir

Audi A6/S6 From 04.04 onwards 130 +/- 10 130 +/- 10
Audi RS 6 From 05.08 onwards 130 +/- 10 Depending on the version of the air
conditioner compressor (refer to note
below)
♦ 130 +/- 10
Note

therefore be adjusted accordingly.
♦ As different versions of this air conditioner compressor are
available as replacement parts, it is important to observe the
exact part number ⇒ Electronic parts catalogue .
♦ On the 10-cyl. TFSI engine (Audi RS 6), an air conditioner
compressor with a smaller refrigerant oil capacity (70 +/ -
10 cm3) than on the 10-cyl. FSI engine (Audi S6) and on other
engines (130 +/ - 10 cm3) is installed due to the differing engine
test procedure; currently the air conditioner compressors of
the 10-cyl. FSI and 10-cyl. TFSI engines only differ in the part
number and the refrigerant oil capacity; also refer to compres‐
sor's label. To adjust the total quantity of oil in the refrigerant
circuit on the 10-cyl. TFSI engine (Audi RS 6), the quantity of
oil that is "missing" in the air conditioner compressor (60 +/ -
10 cm3) is filled into the refrigerant circuit at a different location
during production. This is not necessary during service work
as only replacement air conditioner compressors with the orig‐
inal quantity of oil (130 +/- 10 cm3) are available (this would
only be necessary during service work if a new air conditioner
compressor with the smaller oil capacity was being installed)
10.2.18 Capacities for Audi A6 (4G_ or 4X_ for

China ) 2011 ►, Audi A7 (4G_ or 4X_ for
China) 2011 ►, Audi A6 hybrid (4G_)
2012 ►, A6 e-tron (4G_) 2017 ►
Note
Also applies to Audi S and RS models.

• Expansion valve
• Receiver

hicles except Audi A6 hybrid and A6 e-tron).
• On vehicles with a high-voltage system (Audi A6 e-tron): elec‐
trically driven “Sanden” air conditioner compressors ⇒ Heat‐
sor in cm3
Audi A6 From 02.11 120 +/- 10 120 +/- 10 • “Denso” air conditioner
onwards compressor with oil
separator
onwards pressor type (e.g. “ 6
SEU 14” or “ 6 SBU
14”)
Audi A6 / 06.14 on‐ 110+20 / - 10 110 +/- 10 • “Denso” air conditioner

A7 wards compressor (e.g. type “
6 SES 14” or “ 6 SAS
14”) with oil separator
(with and without air
conditioning system
magnetic clutch -
N25- )
Audi A6 From 11.11 160 +/- 20 160 +/- 20 • Electrically driven air
hybrid onwards conditioner compres‐
sor manufactured by
“Denso”
Audi A6 From 09.16 220+ / - 10 220+ / - 10 • Electrically driven air

e-tron onwards conditioner compres‐
sor manufactured by
“Sanden” (refrigerant
oil SP-A2 ⇒ page 319 )

Note

instead of 4G_.
(and Audi A6 e-tron) were fitted with mechanically driven air
conditioner compressors manufactured by “Denso”. Air con‐
ditioner compressors produced by other manufacturers may
also be fitted at a later date ⇒ Electronic parts catalogue and
♦ At the start of production, the Audi A6 e-tron is fitted with an
electrically driven “Sanden” air conditioner compressor ( elec‐
oil quantity was reduced to 160 ccm. The refrigerant oil does
not have to be reduced on vehicles fitted with an air conditioner
compressor with a refrigerant oil quantity of 200 ccm. Howev‐
er, if the refrigerant circuit has been flushed for example, a
total of 160 ccm should also be filled in in this vehicle as the
specified refrigerant oil quantity. The correct amount of refrig‐
erant oil will already be filled into a replacement air conditioner
compressor ⇒ Electronic parts catalogue .
with an air conditioning system magnetic clutch - N25- fitted
additionally at the pulley will gradually be introduced for certain
engines and models (type “6 SES 14” or “6 SAS 14”) ⇒ Heat‐
will gradually be introduced for which the quantity of refrigerant
oil in the air conditioner compressor is 110 ccm (e.g. type “6
SES 14” or “6 SAS 14”) ⇒ Heating, air conditioning; Rep. gr.
and ⇒ Electronic parts catalogue . On vehicles with such air
conditioner compressors, the quantity of refrigerant oil in the
refrigerant circuit is 110 ccm +20 / -10 ccm (the quantity of
refrigerant oil stipulated for service thus remains 120 ccm +/-
10 ccm).
♦ On the basis of technical product information (TPI), vehicles
manufactured up to and including Model Year 2014 may be
retrofitted with an air conditioner compressor of type “6 SES
14” instead of the air conditioner compressor fitted at the fac‐
tory. A refrigerant oil capacity of 120 ccm remains valid for
such vehicles (if applicable, add 10 ccm of refrigerant oil after
flushing the refrigerant circuit and installing a new air condi‐
tioner compressor).

10.2.19 Capacities for Audi V8 (4C_) ► 1994

• Reservoir
Audi V8 From 10.92 250 + 50 250 + 50
to 10.93
Note


• Restrictor
• Reservoir
Audi A8 From 05.94 250 + 50 250 + 50

Note

♦ Exclusive use was made at the start of production of “Zexel /
onwards, production was gradually switched to “Denso” air
conditioner compressors ⇒ Heating, air conditioning; Rep. gr.
10.2.21 Capacities for Audi A8 (4E_) 2003 ►

• Restrictor
• Reservoir
Vehicle model Production Total quantity of oil in Quantity of refrigerant Differing characteristics
period refrigerant circuit in oil in replacement of this refrigerant circuit
cm3 compressor in cm3
Audi A8 10.02 on‐ 200 +/- 10 200+ / - 10 Air conditioner compres‐
• 8 cyl. petrol en‐ wards sor type “7 SEU 16” (refer
gine with 3.7 ltr. All to notes below)
or 4.2 ltr. (ex‐
cept FSI)
• 6-cyl. and 12- From 10.02 200+ / - 10 200+ / - 10 Air conditioner compres‐
cyl. petrol en‐ to 01.04 sor type “6 SEU 14”, “7
gine SEU 16” or “7 SEU
17” (refer to notes below)
• 6-cyl. and 8-
cyl. diesel en‐
gine
• 6-cyl., 10-cyl. From 01.04 150 +/- 10 150+ / - 10 Air conditioner compres‐
and 12-cyl. pet‐ onwards sor type “6 SEU 14” or “7
rol engine SEU 17” (refer to notes
below)
• 6-cyl. and 8-
cyl. diesel en‐
gine
• 8 cyl. 4.2 ltr.
petrol engine
(FSI only)
Note

tention to the exact part number ⇒ Heating, air conditioning;
♦ At the start of production, the compressor types in the first two
lines of the table were supplied with a refrigerant oil quantity
of 200 cm 3. These air conditioner compressors can be rec‐
ognised from the index of the part number (4E0 260 805 with
index “C”, “D”, “E”, “F”, “J”, “L” or “S”). In Model Year 2004 (as
of approx. 01.04), a gradual change was made to other types
of compressor with a refrigerant oil quantity of 150 cm 3. These
air conditioner compressors can be recognised from the index
of the part number (4E0 260 805 with index “G”, “H”, “T”, “M”,
“N”, “Q” or double index e.g. “AB”) ⇒ Electronic parts cata‐
logue .
10.2.22 Capacities for Audi A8 (4H_) 2010 ►,

Audi A8 hybrid (4H_) 2012 ►
• Expansion valve
air conditioner compressor regulating valve - N280- ⇒ Heat‐
(all vehicles except Audi A8 hybrid).

Caution
Different refrigerant and refrigerant oil capacities for vehicles

with 8-cyl. TDI engine
♦ For vehicles with 8-cylinder TDI engine: Due to the fitting
location of the air conditioner compressor at the top of the
engine, the amount of refrigerant oil required differs from
the quantity indicated on the factory label of the air condi‐
tioner compressor.
Vehicle Pro‐ Total quanti‐ Quantity of Differing

model duction ty of oil in re‐ refrigerant oil characteris‐
period frigerant cir‐ in replace‐ tics of this re‐
cuit in cm3 ment com‐ frigerant cir‐
pressor in cuit
cm3
Audi A8 From
(all en‐ 03.10
gines ex‐ on‐
cept 8- wards
cyl. TDI)
♦ Vehi‐ 130+ / - 10 ♦ 130+ / • One evap‐
cle - 10 orator
with
one
evap‐
orator
♦ Vehi‐ 130+ / - 10 • Two evap‐

cle orators
with (refer to
two notes be‐
evap‐ low)
ora‐
tors
Audi A8
(only 8-
cyl. TDI
engine)
♦ Vehi‐ 180+ / - 10 ♦ 130+ / • One evap‐
cle - 10 orator
with
one
evap‐
orator
♦ Vehi‐ 180+ / - 10 • Two evap‐

cle orators
with (refer to
two notes be‐
evap‐ low)
ora‐
tors

pressor in cuit
cm3
Audi A8 From 160+ / - 20 160+ / - 20 • One evap‐
hybrid 01.12 orator in
on‐ air condi‐
wards tioning
unit
• Electrical‐
ly driven
air condi‐
tioner
compres‐
sor
• Second
evapora‐
tor in bat‐
tery cool‐
ing mod‐
ule

Note
♦ The replacement compressor contains a certain amount of re‐

frigerant oil (currently 130 +/ - 10 cm3 depending on the air
conditioner compressor, refer to label). This quantity of refrig‐
erant oil currently corresponds to the quantity of oil specified
for this refrigerant circuit on vehicles with one or two evapo‐
rators (except vehicles with 8-cyl. TDI engine; for these vehi‐
cles see below). At present, the same amount of oil is used in
vehicles with two evaporators as in vehicles with one evapo‐
rator. Due to the longer refrigerant lines and the second evap‐
orator, no additional refrigerant oil is currently required in the
refrigerant circuit on this vehicle. The refrigerant circuit on this
vehicle is constructed so that only a small part of the refrigerant
oil passes through the refrigerant lines to the second evapo‐
rator and into the second evaporator when the air conditioner
is operated. If the air conditioner compressor is renewed after
cleaning the refrigerant circuit, it is therefore not necessary to
pour additional refrigerant oil into the refrigerant circuit on ve‐
hicles with two evaporators (due to the second evaporator). If
the air conditioner compressor is renewed without having to
clean the refrigerant circuit, the quantity of refrigerant oil in the
new compressor to be fitted should be adjusted in line with the
quantity of oil poured out of the old compressor ⇒ page 258 .
♦ On vehicles with 8-cyl. TDI engine, the quantity of refrigerant
oil in the refrigerant circuit was increased from 130 ccm to
180 ccm from vehicle identification number 4H_ BN 018846
onwards. Accordingly, the refrigerant capacity thus had to be
reduced slightly. As the capacity specification on the label has
not yet been changed, proceed as follows: On vehicles man‐
ufactured up to the vehicle identification number mentioned,
check whether the refrigerant oil has already been topped up
during a previous workshop visit. If not, add 50 ccm of refrig‐
erant oil to the refrigerant circuit. Then correspondingly alter
the refrigerant capacity specified on the label in waterproof ink
and fill the refrigerant circuit with the specified quantity of re‐
frigerant. Finally make a record of the change made in the
vehicle data. On vehicles manufactured as of the vehicle iden‐
tification number mentioned, check the refrigerant capacity
specified on the label, alter accordingly in waterproof ink if ap‐
plicable and then fill the refrigerant circuit with the specified
quantity of refrigerant.
♦ Vehicles with an 8-cyl. TDI engine up to vehicle identification
number 4H_ BN 018845 were filled at the factory with the same
quantity of refrigerant oil as for the other engines. As of vehicle
identification number 4H_ 018846, the refrigerant circuit on
vehicles with an 8-cyl. TDI engine is filled at the factory with a
larger quantity of refrigerant oil. This quantity of refrigerant oil
applies retroactively to all vehicles with an 8-cyl. TDI engine.
If the refrigerant circuit is re-charged on vehicles with an 8-cyl.
TDI engine or the air conditioner compressor is renewed, e.g.
after cleaning the refrigerant circuit, the quantity of refrigerant
oil in the refrigerant circuit must be checked and topped up if
necessary, or the correct quantity must be added (e.g. at open
lines or component connections or via air conditioner service
station prior to filling with refrigerant). If the air conditioner
compressor is renewed without having to clean the refrigerant
circuit, the quantity of refrigerant oil in the new compressor to
be fitted should be adjusted in line with the quantity of oil pour‐
ed out of the old compressor (and topped up accordingly if
necessary on vehicles up to the vehicle identification number
specified above) ⇒ page 258 .

♦ As replacement air conditioner compressors with different oil
capacities are available, it is important to observe the exact
part number ⇒ Electronic parts catalogue .
♦ Too much oil in the circuit results in higher pressures and a
reduction in the cooling output of the air conditioner. Too little
oil may lead to lubrication problems in the air conditioner com‐
pressor. Therefore it is important to observe the specified
refrigerant oil quantities.
were fitted with mechanically driven air conditioner compres‐
sors manufactured by “Denso”. Air conditioner compressors
produced by other manufacturers may also be fitted at a later
date ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
oil quantity was reduced to 160 ccm. The refrigerant oil does
not have to be reduced on vehicles fitted with an air conditioner
compressor with a refrigerant oil quantity of 200 ccm. Howev‐
er, if the refrigerant circuit has been flushed for example, a
total of 160 ccm should also be filled in in this vehicle as the
specified refrigerant oil quantity. The correct amount of refrig‐
erant oil will already be filled into a replacement air conditioner
compressor ⇒ Electronic parts catalogue .
10.2.23 Capacities for Audi Q7 (4L_) 2006 ►

Capacities for Audi Q7 (4L_) 2006 ►
• Expansion valve


pressor in cuit
cm3
Audi Q7 From
(4L_) 02.06
on‐
wards
♦ Vehi‐ 140, 150 or ♦ 140+/- 10 • One evap‐
cle 160+ 15/- 10 (air con‐ orator
with (depending ditioner
one • Air condi‐
on the air compres‐ tioner
evap‐ conditioner sor for ve‐
orator compres‐
compressor hicle with sor type “6
fitted) 6-cyl. TDI SEU 14”
engine or or “7 SEU
12-cyl. 16” (refer
engine) to notes
♦ 150+/- 10 below)
♦ Vehi‐ 240, 250 or (air con‐ • Two evap‐

cle + ditioner orators
260 compres‐
with 15/- 10 (de‐ (refer to
two sor for ve‐ notes be‐
pending on hicle with
evap‐ air condi‐ low)
ora‐ 8-cyl. en‐
tioner com‐ gine or 6-
tors pressor fit‐ cyl. 3.2 l
ted, quantity FSI en‐
of refriger‐ gine)
ant oil in air
conditioner ♦ 160+/ - 10
compressor (air con‐
plus 100) ditioner
compres‐
sor for ve‐
hicle with
6-cyl. 3.6
l FSI en‐
gine)
Note
♦ The replacement compressor contains a certain amount of re‐

frigerant oil (currently 140, 150 or 160 +/- 10 cm3 depending
on the air conditioner compressor). This quantity of refrigerant
oil currently corresponds to the quantity of oil specified for this
refrigerant circuit on vehicles with one evaporator. Because of
the longer refrigerant lines and the second evaporator, vehi‐
cles with two evaporators require more refrigerant oil in the
refrigerant circuit (currently an additional 100 cm3). If the air
conditioner compressor is renewed after cleaning the refrig‐
erant circuit, this quantity of refrigerant oil therefore has to be
added to the refrigerant circuit on vehicles with two evapora‐
tors (e.g. poured into open pipes or component connections).
If the air conditioner compressor is renewed without having to
clean the refrigerant circuit, the quantity of refrigerant oil in the
new compressor to be fitted should be adjusted in line with the
quantity of oil poured out of the old compressor ⇒ page 258 .
10.2.24 Capacities for Audi Q7 (4M_) 2016 ►

Refrigerant oil capacities can be found in the vehicle-specific
Workshop Manual ⇒ Heating, air conditioning; Rep. gr. 00 ;
Technical data; Approved refrigerant oils and capacities for re‐
frigerant oil .
10.2.25 Capacities for Audi R8 (42_) 2008 ►, Audi R8 (4S_) 2015 ►

Characteristics of refrigerant circuit for Audi R8 (42_) 2008 ►:
• Restrictor
• Reservoir
Characteristics of refrigerant circuit for Audi R8 (4S_) 2015 ►:
• Expansion valve
• Receiver (with dryer)

Vehicle model Production Total quantity of oil in Quantity of refrigerant Differing characteristics
period refrigerant circuit in oil in replacement of this refrigerant circuit
cm3 compressor in cm3
Audi R8 (42_) From 03.07 to 200 + /- 10 200+ / - 10 Air conditioner compres‐
11.12 ♦ As of 11.12 the ♦ Depending on the sor type “7 SEU 17”
quantity of oil for part number, re‐
these vehicles was placement air con‐
increased from ditioner compres‐
150 to 200 cm3; sors may contain
this also applies to only 150 cm3; if
all earlier vehicles. necessary add an
additional 50 cm3
(see notes below).
From 11.12 200 + /- 10 200 + /- 10

onwards
Audi R8 (4S_) From 08.15 150 + /- 10 150 + /- 10 Air conditioner compres‐
onwards sor type “6 SES 14”
Note

♦ From vehicle identification number 429 DN 000751 onwards
(manufactured from 11.2013), the quantity of refrigerant in the
circuit was increased from 650 g to 680 g and the quantity of
refrigerant oil from 150 ccm to 200 ccm. The increased amount
of refrigerant and refrigerant oil also applies to all earlier ve‐
hicles. On vehicles manufactured up to the vehicle identifica‐
tion number mentioned, check whether the refrigerant oil has
already been topped up during a previous workshop visit. If
not, add 50 ccm of refrigerant oil to the refrigerant circuit. Then
check the refrigerant capacity indicated on the label and if
necessary attach a new label with the correct capacity and the
appropriate language (e.g. the label with part number
420 010 535 and index BA in German and English) ⇒ Elec‐
gr. 87 ; Installation location overview - Air conditioning (vehi‐
cle-specific Workshop Manual). If no label with the correct
capacity and the appropriate language is available, alter the
capacity indicated on the existing label accordingly with a wa‐
terproof pen. Then increase the refrigerant oil quantity in the
refrigerant circuit by 50 ccm and charge the refrigerant circuit
with the quantity of refrigerant shown above
⇒ “10.1.23 Capacities for Audi R8 (42_) 2008 ►, Audi R8 (4S_)
2015 ►”, page 316 .
quantity of refrigerant oil in the compressor (on the Audi R8
this type plate is not visible when the compressor is installed).
On vehicles up to the vehicle identification number quoted
above, where the air conditioner compressor was filled with a
smaller quantity of refrigerant oil at the factory, make a note in
the vehicle documentation (and on the label indicating the re‐
frigerant capacity) to show that the quantity of refrigerant oil
has already been increased by 50 ccm in the workshop.
ties. Too much oil in the refrigerant circuit results in higher
pressures and a reduction in the cooling output of the air con‐
ditioner. Too little oil may lead to lubrication problems in the
air conditioner compressor. Therefore it is important to ob‐
serve the specified refrigerant oil quantities.

11 Test equipment and tools

⇒ “11.1 List of testers, tools and materials”, page 361
⇒ “11.2 Tools and materials available from regional sales centre
or importer”, page 363
⇒ “11.3 Commercially available tools and materials”, page 366
⇒ “11.4 Improvised tools”, page 367
11.1 List of testers, tools and materials
Note
This list outlines the testers, tools and materials required for ex‐
pert refrigerant circuit repair work.
♦ Tools and materials available from regional sales centre or

importer ⇒ page 361 .
♦ Commercially available tools and materials ⇒ page 362 .
♦ Improvised tools ⇒ page 363 .
11.1.1 Tools and materials available from regional sales centre or importer
Overview Page
Air conditioner service station with flushing kit for currently available air See Figure and ⇒ Electronic parts
conditioner service stations ⇒ Electronic parts catalogue (Tools; Work‐ catalogue
shop equipment/tools; Air conditioning/heating)
– With integrated program for flushing refrigerant circuit with refrigerant
R134a as well as the corresponding flushing kit
Refrigerant circuit flushing kit for currently available flushing kits ⇒ Elec‐ ⇒ Electronic parts catalogue.
tronic parts catalogue (Tools; Workshop equipment/tools; Air condition‐
ing/heating)
– For flushing the refrigerant circuit with refrigerant R134a; also for use
with older air conditioner service stations with a vessel for at least 10
kg of refrigerant R134a (flushing must be performed manually)
VW/Audi passenger vehicle adapter set - VAS 6338/1- ⇒ Electronic parts ⇒ Electronic parts catalogue.
catalogue (Tools; Workshop equipment/tools; Air conditioning/heating).
– For connecting air conditioner service station to refrigerant circuit and
for bridging certain removed components when flushing
Adapters -VAS 6338/40- and -VAS 6338/41- ⇒ Electronic parts catalogue ⇒ Electronic parts catalogue.
(Tools; Workshop equipment/tools; Air conditioning/heating)
– For vehicle with a high-voltage system, for flushing the air conditioner
compressor
Shut-off valve -VAS 6338/42- ⇒ Electronic parts catalogue (Tools; Work‐

shop equipment/tools; Air conditioning/heating)
– For vehicles with a high-voltage system, for bypassing certain re‐
moved components when flushing the refrigerant circuit
Shut-off valve set -VAS 6338/47- ⇒ Electronic parts catalogue (Tools; ⇒ Electronic parts catalogue.
Workshop equipment/tools; Air conditioning/heating)
– For some vehicles with a high-voltage system (e.g. Audi Q7 e-tron);
for bypassing removed non-return valves when flushing the refrigerant
circuit
Leak detector, currently available leak detectors⇒ Electronic parts cata‐ See Figure and ⇒ Electronic parts
logue (Tools; Workshop equipment/tools; Air conditioning/heating) catalogue
Detaching device for magnetic clutch (Zexel / Valeo air conditioner com‐ See Figure and ⇒ Electronic parts
pressor) V.A.G 1719 ⇒ Electronic parts catalogue (Tools; Workshop catalogue
equipment/tools; Air conditioning/heating)
11. Test equipment and tools 361

Overview Page
Adapter set for refrigerant circuit R134a V.A.G 1785/1-10 ⇒ Electronic See Figure and ⇒ Electronic parts
parts catalogue (Tools; Workshop equipment/tools; Air conditioning/heat‐ catalogue
ing)
– For connecting air conditioner service station to refrigerant circuit and
for bridging certain components on flushing and blowing out
Valve adapter V.A.G 1785/9 and V.A.G 1785/10 ⇒ Electronic parts cata‐ See Figure and ⇒ Electronic parts
Adapter set with service connection V.A.G 1786 ⇒ Electronic parts cata‐ See Figure and ⇒ Electronic parts
O-rings ⇒ Electronic parts catalogue See Figure and ⇒ Electronic parts
catalogue
Refrigerant oil ⇒ Electronic parts catalogue See Figure and ⇒ Electronic parts
catalogue
The VAS 6201 leak detection system includes the following: ⇒ Electronic See Figure and ⇒ Electronic parts
parts catalogue (Tools; Workshop equipment/tools; Air conditioning/heat‐ catalogue
ing)
♦ Hand pump with low-pressure service hose, service coupling and non-
return valve VAS 6201/1
♦ Cartridge VAS 6201/2
♦ Cleaning solution VAS 6201/3
♦ UV leak detection lamp VAS 6201/4
♦ Replacement bulb for leak detection lamp VAS 6201/5
♦ Eye protection VAS 6201/6
♦ Sticker VAS 6201/7
♦ Protective gloves VAS 6201/9
♦ Filler tube VAS 6201/8
♦ System case VAS 6201/10
Adapter set for service connections ⇒ Electronic parts catalogue (Tools; See Figure and ⇒ Electronic parts
Workshop equipment/tools; Air conditioning/heating) catalogue
Refrigerant line release tool -T40149/- ⇒ Electronic parts catalogue ⇒ Electronic parts catalogue.
(Tools; Special tools)
Dismantling tool for the refrigerant line quick release couplings -T40232- ⇒ Electronic parts catalogue.
⇒ Electronic parts catalogue (Tools; Special tools)
11.1.2 Commercially available tools and materials

Overview Page
Fin comb Refer to illustration
Filler hoses 5/8" - 18 UNF with valve opener Refer to illustration
Connection piece for refrigerant cylinder and seal with quick-release coupling Refer to illustration
connection or threaded connection 5/8" - 18 UNF
Valve caps 5/8"-18 UNF Refer to illustration
Pressure gauge set with pressure reducer for nitrogen Refer to illustration
Quick-release coupling adapter for service connections (2x included in scope Refer to illustration
of delivery of air conditioner service station)
Open-ring spanner, size according to bolted joints at refrigerant lines Not illustrated
Valve opener for filler hoses Not illustrated
Connecting nipples for conical seal 5/8"-18 UNF Not illustrated
Compressed air gun with rubber end piece Not illustrated

Overview Page
Combination fine filter unit for compressed air system, oil, dirt and water sep‐ Not illustrated
arator as standard for painting facilities
Valve opener for Schrader valve Not illustrated
Manual shut-off valve 5/8"-18 UNF Not illustrated
Recycling cylinder for refrigerant R134a Not illustrated
Digital thermometer Not illustrated
Protective gloves Not illustrated
Safety goggles Not illustrated
Refrigerant R134a with cylinder (capacity as required) Not illustrated
11.1.3 Improvised tools

Overview Page
Filler hose with connection to compressed-air system for workshop Not illustrated
11.2 Tools and materials available from re‐

gional sales centre or importer
Service station / air conditioner service station (this illustration
shows V.A.S 6007A, for example), for currently available air con‐
ditioner service stations ⇒ Electronic parts catalogue (Tools;
Workshop equipment/tools; Air conditioning/heating).
♦ The operations "testing, extraction (recycling), evacuation,
flushing and charging" must be performed according to the
relevant operating instructions.
♦ The filters and dryers fitted must be renewed by no later than
the end of the period of use specified in the operating instruc‐
tions and each time the station is drained (have replacement
filter to hand). Available from equipment manufacturer; refer
to the operating instructions for the air conditioner service sta‐
tion.
♦ Air conditioner service stations that are not displayed here
may also be used ⇒ Electronic parts catalogue (Tools; Work‐
♦ Currently available air conditioner service stations are provi‐
ded with a refrigerant circuit flushing program. The scope of
delivery of these air conditioner service stations also includes
the necessary flushing kit ⇒ Electronic parts catalogue (Tools;
Workshop equipment/tools; Air conditioning/heating).
Note
♦ This air conditioner service station comprises the following

standard components: Charging cylinder, pressure gauge set,
vacuum pump, shut-off valves and filler hoses.
♦ One quick-release coupling each (for service connections on
high and low-pressure side) is included in the scope of delivery
of this air conditioner service station.
♦ Depending on the version, a current vacuum display (LED)
may appear after pressing the “Evacuation” button again.

Leak detector (e.g. V.A.G 1796), currently available leak detec‐

tors⇒ Electronic parts catalogue (Tools; Workshop equipment/
tools; Air conditioning/heating)
Leak detector (e.g. VAS 6201), currently available leak detector

systems ⇒ Electronic parts catalogue (Tools; Workshop equip‐
ment/tools; Air conditioning/heating)
Puller for magnetic clutch V.A.G 1719 (for “Zexel / Valeo” air con‐
ditioner compressor)
Adapter set for refrigerant circuit R134a V.A.G 1785/1-10

Adapter for cleaning refrigerant circuit (flush with refrigerant
R134a) ⇒ page 88 or blow out with compressed air and nitrogen
⇒ page 84 .
A - 5/8"-18 UNF thread for conical seal
B - Union nut (for connection with O-ring) with thread
♦ M 18x1.5 V.A.G 1785/1
♦ M 20x1.5 V.A.G 1785/2
♦ M 24x1.5 V.A.G 1785/3
♦ M 28x1.5 V.A.G 1785/4

Adapter
B - Threaded connection for O-ring
♦ M 18 x 1.5 V.A.G 1785/5
♦ M 20 x 1.5 V.A.G 1785/6
♦ M 24 x 1.5 V.A.G 1785/7
♦ M 28 x 1.5 V.A.G 1785/8
Valve adapter
B - Internal thread with valve opener
♦ M 10 x 1.25 V.A.G 1785/9 (for connections with valve on high-
pressure end)
♦ M 12 x 1.5 V.A.G 1785/10 (for connections on low-pressure
end)
Note
♦ A Schrader valve is screwed into connection -A-.

♦ A valve opener must be installed in the filler hose connection.
♦ Various adapters from this adapter set are also included in the
VW/Audi passenger vehicle adapter set - VAS 6338/1- .
Adapter set for service connection V.A.G 1786

A - Adapter with union nut - V.A.G 1786/1- (only for connections
with small valve core at low-pressure side)
B - Filler hose with union nut 5/8"-18 UNF (short version)
C - Adapter with service connection - V.A.G 1786/2-
Note
♦ For connections with large valve core (standard on “Zexel/Va‐

leo” compressors, gradual change to small valve core from
10.94 onwards), adapter V.A.G 1785/10 should be used (re‐
move valve from adapter V.A.G 1785/10 or install valve open‐
er in filler hose -B-).

Socket - T10364-
Note
For removing and installing service connections and valve cores

with refrigerant circuit discharged.
11.3 Commercially available tools and mate‐

rials
Fin comb
Filler hoses
5/8"-18 UNF thread
Note
♦ Use differently coloured filler hoses (1800 mm long).

♦ Have valve opener and spare seals to hand.
♦ A short filler hose is also included in the adapter set for refrig‐
erant circuits - VAS 6338/1- .
Connection piece for refrigerant cylinder with seal, quick-release

coupling connection or threaded connection 5/8" - 18 UNF

Valve caps with spare seals (for 5/8"-18 UNF thread)

Seals can also be used for filler hoses.
Note
Valve caps with replacement seals are also included in the adapt‐
er set for refrigerant circuits - VAS 6338/1- .
Pressure gauge set with nitrogen pressure reducer (max. reduc‐

ing pressure: 15 bar).
1- Pressure gauge set
2- Pressure hose (ID 5 mm, length 2 m)
3- Nitrogen
4- Hose fitting
Note
For connection to adapter V.A.G 1785 with 5/8"-18 UNF thread
Quick-release coupling adapter for service connections

♦ High-pressure side with nominal diameter of 16 mm
♦ Low-pressure side with nominal diameter of 13 mm
♦ Sharan, 2 releasing tools
Note
This quick-release coupling is included in the scope of delivery of

the air conditioner service station.
11.4 Improvised tools

Filler hose with connection to compressed-air system for work‐
shop
A - Filler hose 5/8" - 18 UNF** (version with large internal diam‐
eter)
B - Connection for workshop compressed air system** (always
use filter)

SM 57

Uploaded by

SM 57

Uploaded by

Service

Service Department. Technical Information

Audi Q3 2019 ➤ , Audi Q3 China 2013 ➤ ,

Service Department. Technical Information

Technical information should always be available to the foremen and mechanics,

All rights reserved.

Copyright © 2019 Audi AG, Ingolstadt A0053300220

All rights reserved.

Copyright © 2019 Audi AG, Ingolstadt A0053300220

87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

87 – Air conditioning system

1.1 Safety precautions when working on air conditioners

Risk of irreparable damage to refrigerant lines

1.2 Safety precautions when handling refrigerants

Risk of frostbite from refrigerant

1.3 Safety precautions when working on vehicles with start/stop system

1.4 Safety precautions when working on vehicles with high-voltage system

Risk of injury - engine may start unexpectedly

2 Rep. gr.87 - Air conditioning system

– Switch off ignition.

Risk of injury if auxiliary air conditioner is activated

1.5 Safety precautions when working in the vicinity of high-voltage components

Risk of damage to high-voltage wiring

4 Rep. gr.87 - Air conditioning system

2 General information on air condition‐

This requires careful study of the manual, coupled with suitable

This document is a compact reference work which should be kept

2.2 Other reference material

2. General information on air conditioning systems 5

♦ Workshop Manual: Air conditioner with refrigerant R12 (for

2.3 Principles of air conditioning systems

2.3.1 Physical principles

When water is heated in a vessel (heat absorption), water vapour

2.3.2 Pressure and boiling point

6 Rep. gr.87 - Air conditioning system

Pressure can be measured in various units: 1 MPa (megapascal)

For example, water boils at a lower temperature the lower the

Vapour pressure curve for refrigerant R134a

2.3.3 Vapour pressure table for refrigerant

2. General information on air conditioning systems 7

♦ “0 bar absolute pressure” corresponds to an absolute vacuum.

Temperature in °C Pressure in bar (gauge pres‐

2.4 Refrigerant R134a

8 Rep. gr.87 - Air conditioning system

⇒ “2.4.1 Physical properties of refrigerant R134a”, page 9

2.4.1 Physical properties of refrigerant R134a

2.4.2 Critical point

Different types of refrigerant must never be mixed. The refrigerant

2.4.3 Environmental aspects of refrigerant

2. General information on air conditioning systems 9

2.5 Properties of refrigerant R134a

2.5.1 Trade names and designations

♦ Different trade names may be used in other countries.

2.5.3 Vapour pressure

2.5.4 Physical properties of R134a

10 Rep. gr.87 - Air conditioning system

2.5.5 Reaction with metals

2.5.6 Critical temperature/critical pressure

2.5.7 Water content

2.5.9 Charge factor

2.5.10 Tracing leaks

2. General information on air conditioning systems 11

It is important to use leak detectors that are designed for the

2.6 Refrigerant oil

♦ For information on how to handle refrigerant oil, refer to ⇒

Refrigerant oil mixes with the refrigerant (in a ratio of about

♦ Do not store refrigerant oil in open containers as it is extremely

⇒ “2.6.1 Properties of refrigerant oil”, page 12

2.6.1 Properties of refrigerant oil

12 Rep. gr.87 - Air conditioning system

♦ Due to its chemical properties, refrigerant oil must not be dis‐

♦ A use-by date for the refrigerant oil is stated on the bottle in

2.7 How air conditioning works

2. General information on air conditioning systems 13

⇒ “2.7.1 Comfort of vehicle occupants”, page 14

2.7.1 Comfort of vehicle occupants