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Service: Air Conditioner With Refrigerant R134a

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Service: Air Conditioner With Refrigerant R134a

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sven cornelissens

Available Formats

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Service

Workshop Manual
Audi 100 1991 ➤ , Audi 80 1992 ➤ ,
Audi A1 2011 ➤ , 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 2013 ➤ ,
Audi A3 Sportback China 2014 ➤ ,
Audi A4 1995 ➤ , Audi A4 2001 ➤ ,
Audi A4 2008 ➤ ,
Audi A4 Cabriolet 2003 ➤ ,
Audi A5 Cabriolet 2009 ➤ ,
Audi A5 Coupé 2008 ➤ ,
Audi A5 Sportback 2010 ➤ ,
Audi A6 1995 ➤ , Audi A6 1998 ➤ ,
Audi A6 2005 ➤ , Audi A6 2011 ➤ ,
Audi A6 China 2012 ➤ ,
Audi A7 Sportback 2011 ➤ ,
Audi A8 1994 ➤ , Audi A8 2003 ➤ ,
Audi A8 2010 ➤ , Audi Cabriolet 1991 ➤ ,
Audi Q3 2012 ➤ , Audi Q3 China 2013 ➤ ,
Audi Q5 2008 ➤ , Audi Q5 China 2010 ➤ ,
Audi Q7 2007 ➤ , Audi R8 2007 ➤ ,
Audi TT 1999 ➤ , Audi TT 2007 ➤ ,
Audi TT 2015 ➤
Air conditioner with refrigerant R134a
Edition 11.2014

Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups

Repair Group
87 - Air conditioning system
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Contents

87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Warning instructions when working on vehicles with high-voltage system . . . . . . . . . . . . 1
1.1 Working on vehicles with high-voltage system (hybrid vehicles) . . . . . . . . . . . . . . . . . . . . 1
1.2 Visual inspection of high-voltage components and wiring for damage . . . . . . . . . . . . . . . . 5
2 General information on air conditioning systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Safety measures for vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 Other reference material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5 Principles of air conditioning systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.6 Refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.7 Properties of refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.8 Refrigerant oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.9 How air conditioning works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.10 General work safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.11 Product properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.12 Handling refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.13 Handling pressure vessels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.14 Safety regulations for working with extraction and charging systems . . . . . . . . . . . . . . . . 24
2.15 Safety measures for working on vehicles with air conditioning system and for handling
refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.16 Basic rules for working on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.17 Before using air conditioner after system has been re-charged . . . . . . . . . . . . . . . . . . . . . . 38
3 General information on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.1 Components of refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.2 Layout of components of refrigerant circuit and their influence on high-pressure and low-
pressure sides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.3 Design of refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.4 Refrigerant circuit with electrically driven air conditioner compressor (with and without battery
cooling module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.5 Connections for quick-release coupling in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . 68
3.6 Switches and senders in refrigerant circuit and related connections . . . . . . . . . . . . . . . . 71
3.7 Electrical components not installed in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.8 Pressures and temperatures in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.9 Tests and measurements performed with pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . 82
3.10 Air conditioner service and recycling units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.11 Repair notes for refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4 Laws and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.1 Laws and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5 Refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.1 Important repair notes for air conditioning systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.2 Converting refrigerant circuits from refrigerant R12 to refrigerant R134a . . . . . . . . . . . . . . 90
5.3 Working with the air conditioner service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.4 Blowing out refrigerant circuit with compressed air and nitrogen . . . . . . . . . . . . . . . . . . . . 108
5.5 Cleaning (flushing) refrigerant circuit with refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . 116
5.6 Tracing leaks in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
6 Problems with refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
6.1 Possible complaints about refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
7 Connecting air conditioner service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
7.1 Connecting air conditioner service station - vehicles with a connection on the low-pressure
and high-pressure side of the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
7.2 Connecting air conditioner service station - vehicles with no connection on the low-pressure
side of the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Contents i
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

8 Checking pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

8.1 Checking pressures in refrigerant circuit with air conditioner service station (with ignition
switched off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
8.2 Checking pressures on vehicles with a restrictor and reservoir (with internally regulated air
conditioner compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
8.3 Checking pressures on vehicles with an expansion valve and receiver (with internally
regulated air conditioner compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
8.4 Checking pressures on vehicles with restrictor, reservoir and air conditioner compressor
regulating valve N280 (with externally regulated air conditioner compressor) . . . . . . . . . . 226
8.5 Checking pressures on vehicles with expansion valve, receiver and air conditioner
compressor regulating valve N280 (with externally regulated air conditioner compressor)
........................................................................ 234
8.6 Checking pressures on vehicles with an electrically driven air conditioner compressor
(vehicles with a high-voltage system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
9 Renewing components of refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
9.1 Renewing components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
10 Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils . . . . . . . . . . 294
10.1 Capacities for refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
10.2 Approved refrigerant oils and refrigerant oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
11 Test equipment and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
11.1 List of testers, tools and materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
11.2 Tools and materials available from regional sales centre or importer . . . . . . . . . . . . . . . . 375
11.3 Commercially available tools and materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
11.4 Improvised tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379

ii Contents
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

87 – Air conditioning system

1 Warning instructions when working
on vehicles with high-voltage system
(ARL004082; Edition 11.2014)
Hybrid vehicles
⇒ “1.1 Working on vehicles with high-voltage system (hybrid ve‐
hicles)”, page 1
⇒ “1.2 Visual inspection of high-voltage components and wiring
for damage”, page 5

1.1 Working on vehicles with high-voltage

system (hybrid vehicles)

WARNING

Safety hazard: the engine can start unexpectedly.

Before carrying out general work on a vehicle with high-voltage
electrical system, switch off the ignition and remove the ignition
key from the vehicle.

WARNING

Working on vehicles with high-voltage wiring:

• Do not support yourself or tools on high-voltage wiring or
associated components --> this can damage the insula‐
tion.
• High-voltage wiring must not be excessively bent or
kinked --> this can damage the insulation.
• The round high-voltage connectors are colour-coded with
an external coloured ring and are provided with mechan‐
ical coding or guide lugs. It is important to observe this
coding when joining up the round high-voltage connec‐
tors, otherwise the connectors can be damaged.

1. Warning instructions when working on vehicles with high-voltage system 1

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

DANGER!

Risk of fatal injury if high-voltage components are damaged.

Observe the following when working in the vicinity of high-volt‐
age components or wiring:
♦ It is not permitted to use cutting or forming tools, other
sharp-edged tools or heat sources such as welding, braz‐
ing, soldering, hot air or thermal bonding equipment.
♦ Before starting work, visually inspect the high-voltage
components in the areas involved.
♦ Before working in the engine compartment, visually in‐
spect the power and control electronics for electric drive -
JX1- , electric drive motor - V141- , air conditioner
compressor - V470- and high-voltage wiring.
♦ Before working on the vehicle underbody, visually inspect
the high-voltage wiring and covers.
♦ Before working on the rear section of the vehicle, visually
inspect the high-voltage wiring and the electro-box with
the maintenance connector for high-voltage system - TW
-.
♦ Visually inspect all potential equalisation lines.
Check the following when making the visual inspection:
♦ There must be no external damage on any component.
♦ The insulation of the high-voltage wiring and potential
equalisation lines must not be damaged.
♦ There must be no unusual deformation of the high-voltage
wiring.
♦ All high-voltage components must be identified by a red
warning sticker.

De-energising high-voltage system

DANGER!

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock.
♦ The high-voltage system may only be de-energised by a
suitably qualified person (Audi high-voltage technician).
♦ It must be definitely confirmed that the high-voltage sys‐
tem is de-energised. The system may only be de-ener‐
gised using the vehicle diagnostic tester via “Guided Fault
Finding”.
♦ The qualified person (Audi high-voltage technician) con‐
firms that the system is de-energised and uses the locking
cap - T40262- to ensure that the system cannot be re-
energised. The ignition key and the maintenance connec‐
tor for high-voltage system - TW - should then be stored
in a safe place by the qualified person.
♦ The qualified person (Audi high-voltage technician) marks
the vehicle by attaching the appropriate warning signs.

2 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

♦ De-energising high-voltage system:

♦ Connect vehicle diagnostic tester
♦ Select Guided Fault Finding mode
♦ Using the Go to key, select the following menu items in suc‐
cession
♦ Function/component selection
♦ Body
♦ Electrical system
♦ Self-diagnosis compatible systems
♦ 8C - Hybrid battery management -J840
♦ 8C - Hybrid battery management, functions
♦ 51 - De-energise high-voltage system (Rep. gr. 93)

♦ The system must first be de-energised by an Audi high-voltage

technician before any work is done on the high-voltage system
⇒ Electrical system; Rep. gr. 93 ; De-energising high-voltage
system .
♦ The types of work for which the high-voltage system has to be
de-energised are indicated in the instructions for each proce‐
dure. For further information, see ⇒ Electrical system; Rep.
gr. 93 ; General warning instructions for work on the high-
voltage system .

Note

♦ The high-voltage system must be de-energised prior to begin‐

ning certain work on components of hybrid vehicles that are
connected to the high-voltage system (e.g. electrically driven
air conditioner compressor).
♦ Work on the air conditioning system of hybrid vehicles that
does not directly affect the high-voltage system (e.g. perform‐
ing pressure test on refrigerant circuit, running Guided Fault
Finding for air conditioner or control unit for air conditioning
compressor - J842- etc.) must only be carried out by electri‐
cally instructed persons ⇒ Electrical system; Rep. gr. 93 ;
General warning instructions for work on the high-voltage sys‐
tem and ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
mode for air conditioner and battery power regulation .
♦ For certain work on hybrid vehicle components that are instal‐
led near high-voltage system components (e.g. battery cooling
module, expansion valve to air conditioning unit on Audi Q5),
the high-voltage system must be de-energised prior to begin‐
ning work ⇒ Electrical system; Rep. gr. 93 ; De-energising
high-voltage system and ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit; System overview - refrigerant circuit
(vehicle-specific Workshop Manual).

1. Warning instructions when working on vehicles with high-voltage system 3

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Re-energising high-voltage system

DANGER!

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock.
♦ The high-voltage system may only be re-energised by a
suitably qualified person (Audi high-voltage technician).
♦ The system may only be re-energised using the vehicle
diagnostic tester via “Guided Fault Finding”.
♦ The vehicle is then made ready for operation again by the
qualified person (Audi high-voltage technician).
♦ The qualified person (Audi high-voltage technician) marks
the vehicle by attaching the appropriate warning signs.

Note

♦ Re-energising high-voltage system:

4 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Working with ignition switched on or high-voltage system active

DANGER!

When working on a vehicle with the ignition switched on or

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

– 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 .
– For test and measurement work that requires the vehicle's
drive system to be active (READY) or the ignition to be switch‐
ed on, move the selector lever to position “P”, activate the
parking brake and take care to keep well clear of the engine
when it is running. Set up any tools needed so that they cannot
come into contact with moving parts.

Note

♦ Also move the selector lever to position “P” and activate the
parking brake before performing test and measurement work
for which the ignition must be switched on but where the ve‐
hicle's drive system does not need to be active (READY).
♦ The status of the drive system (READY) is shown by the con‐
trol unit in dash panel insert - J285- via the “power meter” ⇒
Owner's Manual .
♦ Activating and deactivating drive system ⇒ Owner's Manual
(note display of control unit in dash panel insert - J285- ).

1.2 Visual inspection of high-voltage com‐

ponents and wiring for damage

WARNING

Safety hazard: the engine can start unexpectedly.

Before carrying out general work on a vehicle with high-voltage
electrical system, switch off the ignition and remove the ignition
key from the vehicle.

1. Warning instructions when working on vehicles with high-voltage system 5

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

WARNING

Working on vehicles with high-voltage wiring:

DANGER!

Risk of fatal injury if high-voltage components are damaged.

Procedure: Performing visual inspection

♦ When performing the visual inspection in the engine compart‐
ment area, pay particular attention to the power and control
electronics for electric drive, the high-voltage wires for the bat‐
tery and the air conditioner compressor, and the high-voltage
wire for the electric drive motor.
♦ When performing a visual inspection of the vehicle underbody,
pay attention to the high-voltage wiring and the corresponding
covers.

6 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

♦ When performing a visual inspection of the rear of the vehicle,

pay attention to the hybrid battery, the high-voltage wiring for
the battery and the electronics box with the maintenance con‐
nector.
Check the following when performing the visual inspection:
♦ There must be no external damage on any high-voltage com‐
ponents.
♦ The insulation of the high-voltage wiring must be intact and
undamaged.
♦ Check for unusual deformations of the high-voltage wiring.
♦ If you notice anything unusual or if anything is unclear, ask the
responsible Audi high-voltage technician or electrically skilled
person.
♦ For further information on the high-voltage system, refer to ⇒
Electrical system; Rep. gr. 93 ; General warning instructions
for work on the high-voltage system .

1. Warning instructions when working on vehicles with high-voltage system 7

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

8 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

2 General information on air condition‐

ing systems
⇒ “2.1 General notes”, page 9
⇒ “2.2 Introduction”, page 9
⇒ “2.3 Safety measures for vehicles with start/stop system”, page
12
⇒ “2.4 Other reference material ”, page 12
⇒ “2.5 Principles of air conditioning systems”, page 14
⇒ “2.6 Refrigerant R134a”, page 16
⇒ “2.7 Properties of refrigerant R134a”, page 17
⇒ “2.8 Refrigerant oil”, page 19
⇒ “2.9 How air conditioning works”, page 20
⇒ “2.10 General work safety”, page 22
⇒ “2.11 Product properties”, page 22
⇒ “2.12 Handling refrigerant”, page 22
⇒ “2.13 Handling pressure vessels”, page 23
⇒ “2.14 Safety regulations for working with extraction and charg‐
ing systems”, page 24
⇒ “2.15 Safety measures for working on vehicles with air condi‐
tioning system and for handling refrigerant R134a”, page 24
⇒ “2.16 Basic rules for working on refrigerant circuit”, page 29
⇒ “2.17 Before using air conditioner after system has been re-
charged”, page 38

2.1 General notes

⇒ “2.2 Introduction”, page 9
⇒ “2.4 Other reference material ”, page 12
⇒ “2.5 Principles of air conditioning systems”, page 14
⇒ “2.6 Refrigerant R134a”, page 16
⇒ “2.7 Properties of refrigerant R134a”, page 17
⇒ “2.8 Refrigerant oil”, page 19
⇒ “2.9 How air conditioning works”, page 20
⇒ “2.10 General work safety”, page 22
⇒ “2.11 Product properties”, page 22
⇒ “2.12 Handling refrigerant”, page 22
⇒ “2.13 Handling pressure vessels”, page 23
⇒ “2.14 Safety regulations for working with extraction and charg‐
ing systems”, page 24
⇒ “2.15 Safety measures for working on vehicles with air condi‐
tioning system and for handling refrigerant R134a”, page 24
⇒ “2.16 Basic rules for working on refrigerant circuit”, page 29
⇒ “2.17 Before using air conditioner after system has been re-
charged”, page 38

2.2 Introduction

2. General information on air conditioning systems 9

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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.
Vehicles with high-voltage system (hybrid vehicles)
For all work on vehicles with a high-voltage system, note the ad‐
ditional warning instructions for working on such vehicles
⇒ “1 Warning instructions when working on vehicles with high-
voltage system”, page 1 and ⇒ Electrical system; Rep. gr. 93 ;
General warning instructions for work on the high-voltage sys‐
tem .

WARNING

Safety hazard: the engine can start unexpectedly.

Before carrying out general work on a vehicle with high-voltage
electrical system, switch off the ignition and remove the ignition
key from the vehicle.

WARNING

Working on vehicles with high-voltage wiring:

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DANGER!

Risk of fatal injury if high-voltage components are damaged.

Vehicles with start/stop system

WARNING

Injury risk due to automatic engine start (vehicles with start/

stop system).
♦ On vehicles with an activated start/stop system (indicated
by a message in the instrument cluster display), the en‐
gine may start automatically on demand.
♦ Therefore, please make sure that the start/stop system is
deactivated when performing repair work on the vehicle
(switch off the ignition, and switch it on again if required).

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All vehicles

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.

2.3 Safety measures for vehicles with start/

stop system

WARNING

Injury risk due to automatic engine start (vehicles with start/

2.4 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
♦ Workshop Manual: Air conditioner with refrigerant R12 (for
vehicles built up to model year 1993; this Workshop Manual is
available in hardcopy form only)
Vehicles with high-voltage system (hybrid vehicles)
For all work on vehicles with a high-voltage system, note the
warning instructions for working on such vehicles
⇒ “1 Warning instructions when working on vehicles with high-
voltage system”, page 1 and ⇒ Electrical system; Rep. gr. 93 ;
General warning instructions for work on the high-voltage sys‐
tem .

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WARNING

Safety hazard: the engine can start unexpectedly.

Before carrying out general work on a vehicle with high-voltage
electrical system, switch off the ignition and remove the ignition
key from the vehicle.

WARNING

Working on vehicles with high-voltage wiring:

DANGER!

Risk of fatal injury if high-voltage components are damaged.

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2.5 Principles of air conditioning systems

⇒ “2.5.1 Physical principles”, page 14
⇒ “2.5.2 Pressure and boiling point”, page 14
⇒ “2.5.3 Vapour pressure table for refrigerant R134a”,
page 15
⇒ “2.7 Properties of refrigerant R134a”, page 17

2.5.1 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.

2.5.2 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.

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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

2.5.3 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

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Temperature in °C Pressure in bar (gauge pres‐

sure), R134a
-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

2.6 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).
⇒ “2.6.1 Physical properties of refrigerant R134a”, page 16
⇒ “2.6.2 Critical point”, page 17
⇒ “2.6.3 Environmental aspects of refrigerant R134a”,
page 17

2.6.1 Physical properties of refrigerant R134a

Chemical formula CH2F–CF3 or CF3–CH2F
Chemical designation Tetrafluoroethane
Boiling point at 1 bar -26.5 ℃
Solidification point -101.6 ℃
Critical temperature 100.6 ℃

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Critical pressure 40.56 bar (absolute)

2.6.2 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 15 “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.

2.6.3 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 1300 (GWP
of carbon dioxide = 1).
♦ The global warming effect of R134a is ten times less than that
of refrigerant R12.

2.7 Properties of refrigerant R134a

⇒ “2.7.1 Trade names and designations”, page 17
⇒ “2.7.2 Colour”, page 18
⇒ “2.7.3 Vapour pressure”, page 18
⇒ “2.7.4 Physical properties of R134a”, page 18
⇒ “2.7.5 Reaction with metals”, page 18
⇒ “2.7.6 Critical temperature/critical pressure”, page 18
⇒ “2.7.7 Water content”, page 18
⇒ “2.7.8 Combustibility”, page 19
⇒ “2.7.9 Charge factor”, page 19
⇒ “2.7.10 Tracing leaks”, page 19

2.7.1 Trade names and designations

The refrigerant R134a is currently available under the following
trade names:
♦ H-FKW 134a
♦ SUVA 134a

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♦ 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.

2.7.2 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.

2.7.3 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 15 “Vapour pressure table”.

2.7.4 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).

2.7.5 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.

2.7.6 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").

2.7.7 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.

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Water causes irreparable damage to the air conditioner because

at high pressures and temperatures it combines with other im‐
purities to form acids.

2.7.8 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.

2.7.9 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.

2.7.10 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.

2.8 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 refrigerant) 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

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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. It must be disposed of as used
oil of unknown origin (observe local regulations) ⇒ Audi Serv‐
iceNet, 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).

⇒ “2.8.1 Properties of refrigerant oil”, page 20

2.8.1 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 332 .
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 ingress of moisture. 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 332 .

2.9 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.

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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.
⇒ “2.9.1 Comfort of vehicle occupants”, page 21
⇒ “2.9.2 Environmental aspects”, page 21

2.9.1 Comfort of vehicle occupants

A basic requirement for concentration and safe driving is a feeling
of comfort in the passenger compartment. Especially when con‐
ditions 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 in‐
creasing the air delivery. 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 ℃ 42 ℃
At chest level 24 ℃ 40 ℃
In footwell 30 ℃ 35 °C

2.9.2 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).

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For environmental reasons, refrigerants must not be released into

the atmosphere ⇒ page 85 (see the relevant environmental leg‐
islation).

2.10 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.

2.11 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:

2.12 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 from coming into
contact with eyes, as this could cause severe injury (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).

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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.
⇒ “2.13 Handling pressure vessels”, page 23

2.13 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.

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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 the
ingress of moisture. 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.

2.14 Safety regulations for working with ex‐

traction and charging systems
• Before connecting the charging system to the air conditioning
system, ensure that the shut-off valves are closed.
• Before disconnecting the charging system from the air condi‐
tioning system, make sure the charging process has been
completed to prevent refrigerant escaping into the atmos‐
phere.
• Once the purified refrigerant from the charging system has
been transferred to an external compressed-gas cylinder,
close the hand shut-off valves at the cylinder and charging
system.
• Do not expose the charging system to moisture or use it in a
wet environment.
• Disconnect from power supply before performing service work
on the charging system.
• An extension cable should not normally be used because it
can increase the fire hazard. If the use of an extension cable
is unavoidable, the minimum cross-section should be 2.5
mm2.
• In case of fire, remove external cylinder.
• If any oil from the air conditioning system is drawn off by the
suction unit into the measuring container provided, it must be
subsequently transferred to a sealable container, as it con‐
tains a small quantity of refrigerant, which must not escape
into the environment.
• Following shutdown, the air conditioner service station must
be secured to stop it rolling away.

2.15 Safety measures for working on vehi‐

cles with air conditioning system and for
handling refrigerant R134a
Vehicles with high-voltage system (hybrid vehicles)
For all work on vehicles with a high-voltage system, note the ad‐
ditional warning instructions for working on such vehicles
⇒ “1 Warning instructions when working on vehicles with high-
voltage system”, page 1 and ⇒ Electrical system; Rep. gr. 93 ;
General warning instructions for work on the high-voltage sys‐
tem .

24 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

WARNING

Safety hazard: the engine can start unexpectedly.

Before carrying out general work on a vehicle with high-voltage
electrical system, switch off the ignition and remove the ignition
key from the vehicle.

WARNING

Working on vehicles with high-voltage wiring:

DANGER!

Risk of fatal injury if high-voltage components are damaged.

2. General information on air conditioning systems 25

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
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Vehicles with start/stop system

WARNING

Injury risk due to automatic engine start (vehicles with start/

26 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

All vehicles

WARNING

Danger of asphyxiation, frostbite and poisoning from escaping

refrigerant
Injury risk due to escaping refrigerant
♦ Danger of asphyxiation from displacement of ambient air
♦ Danger of frostbite (or risk of cryogenic burns caused by
the evaporation of liquid refrigerant).
♦ Danger of poisoning from decomposition products
Precautionary measures
• Work may only be performed on the refrigerant circuit of
an air conditioning system in well ventilated areas.
• Ensure good ventilation when handling refrigerant and
working on the refrigerant circuit (exchange of air at least
1 once per hour in workshops and 3 times per hour in low-
level areas (e.g. inspection pits). Switch on workshop
exhaust extraction system.
• Vessels and devices containing refrigerant are only to be
stored in well ventilated areas (e.g. not in cellars or in the
vicinity of cellar entrances).
• Never inhale escaping refrigerant vapours.
• Wear suitable protective gloves and safety goggles when
handling refrigerant and working on the refrigerant circuit.
• It is advisable to keep an eye bath to hand.
• Work may only be performed on the refrigerant circuit of
an air conditioning system in well ventilated areas. Switch
on workshop extraction systems, if available.
• Refrigerant must not be stored in low-level areas (e.g. cel‐
lars) and their exits or light wells.
First aid
• Following inhalation of highly concentrated refrigerant va‐
pours, the person concerned is to be removed immedi‐
ately from the hazard area and laid down in the open air.
Keep the person concerned warm and calm. Perform ar‐
tificial respiration in the event of breathing difficulties (ad‐
minister oxygen if necessary). If the person affected is
having great difficulty breathing or is not breathing at all,
tilt back head and administer artificial respiration. Consult
a doctor.
• Should liquid refrigerant come into contact with the eyes,
rinse them thoroughly with water for about 15 minutes.
Then administer eye drops and consult a doctor immedi‐
ately even if no pain is felt.
• Never attempt to administer liquids through the mouth of
an unconscious person. Consult a doctor if the symptoms
persist and in cases of doubt.
• The doctor must be informed that the frostbite was caused
by refrigerant R 134a. Should refrigerant come into con‐
tact with other parts of the body even though the safety
precautions have been observed, these components must
also be rinsed with cold or lukewarm water immediately
for approx. 15 minutes.

2. General information on air conditioning systems 27

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• Following accidental contact with eyes or mucous mem‐

branes, immediately rinse with copious amounts of run‐
ning water and consult an eye specialist.
• In the event of skin contact, immediately remove wet cloth‐
ing and rinse the areas of skin affected with a copious
amount of cold or luke warm water (never use hot water).
Consult a doctor in the event of frostbite.

Note

♦ The refrigerant has a scarcely perceptible odour and is thus

not noticeable.
♦ The refrigerant gas is heavier than air and accumulates in low-
level areas such as inspection pits, cellars and hollows, where
it displaces the ambient air and thus the oxygen. A lack of
oxygen in the atmosphere is potentially fatal.
♦ Liquid refrigerant escaping from a leak for example evapo‐
rates at an ambient pressure of approx. 1 bar at around -29.4
°C. If the refrigerant evaporates on the skin, it will cause frost‐
bite or cryogenic burns. Sensitive parts of the body such as
the cornea of the eye are particularly at risk. Large-scale cryo‐
genic burns are potentially fatal.
♦ The refrigerant decomposes if it comes into contact with a
flame or a hot surface. Danger of poisoning on inhaling toxic
decomposition products. A pungent odour indicates that prod‐
ucts of decomposition have already developed. Do NOT in‐
hale these substances, otherwise the respiratory tract, lungs
and other organs could be damaged.
♦ The specific hazards associated with refrigerant and the sub‐
stance data etc. can be found in the safety data sheets. Safety
data sheets for the refrigerant, refrigerant oil, etc. can be found
in the “Audi ServiceNet.”
♦ The following procedure is an example of how to access the
“Audi ServiceNet” in Germany. The submenu may be different
in other countries. For precise details of how to find the “safety
data sheets”, follow the directions given in the “Audi Service‐
Net”.

Example of how to search for the safety data sheets in the “Audi
ServiceNet” ⇒ table
– Select path:
Audi ServiceNet
Handbooks
HSO
Environmental Protection
Safety Data Sheets
Safety Data Sheets and Operating Instruc‐
tions
– Select the range criteria.
– Enter the data on the material master (e.g. the part number or
trade name).
Welding, brazing and soldering work must not be performed on
components of air conditioning system when charged. This also
applies to welding and soldering work on the vehicle if there is a
danger of air conditioner components becoming hot. When per‐

28 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

forming paintwork repairs, the temperature in the drying booth or

preheating zone must not exceed 80 °C.
Reason:
Exposure to heat generates considerable pressure in the system,
which could cause the high-pressure safety valve to open.
Remedy:
– Discharge refrigerant circuit using air conditioner service sta‐
tion.

Note

Damaged or leaking components of the air conditioning system

must not be repaired by welding or soldering. They must always
be renewed.

Refrigerant vessels (e.g. charging cylinders of air conditioner

service station) must never be subjected to excessive heat or ex‐
posed to direct sunlight.
Remedy:
– Vessels must never be completely filled with liquid refrigerant.
Without sufficient room for expansion (gas cushion), vessels
will rupture with explosive effect in the event of an increase in
temperature ⇒ page 17 .
Refrigerant should never be poured into systems or vessels con‐
taining any air.
Remedy:
– Evacuate systems and containers before charging with refrig‐
erant.

2.16 Basic rules for working on refrigerant cir‐

cuit
Vehicles with high-voltage system (hybrid vehicles)
For all work on vehicles with a high-voltage system, note the ad‐
ditional warning instructions for working on such vehicles
⇒ “1 Warning instructions when working on vehicles with high-
voltage system”, page 1 and ⇒ Electrical system; Rep. gr. 93 ;
General warning instructions for work on the high-voltage sys‐
tem .

WARNING

Safety hazard: the engine can start unexpectedly.

Before carrying out general work on a vehicle with high-voltage
electrical system, switch off the ignition and remove the ignition
key from the vehicle.

2. General information on air conditioning systems 29

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
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WARNING

Working on vehicles with high-voltage wiring:

DANGER!

Risk of fatal injury if high-voltage components are damaged.

If work is necessary in the vicinity of high-voltage system com‐

ponents, perform a visual inspection of the high-voltage compo‐
nents and wiring to check for damage ⇒ page 5 and note ⇒
Electrical system; Rep. gr. 93 ; General warning instructions for
work on the high-voltage system .
If work is necessary on components of the high-voltage system,
de-energise the high-voltage system ⇒ Electrical system; Rep.
gr. 93 ; De-energising high-voltage system and note ⇒ Electrical

30 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

system; Rep. gr. 93 ; General warning instructions for work on

the high-voltage system .
De-energising high-voltage system

DANGER!

High voltage can cause fatal injury.

Note

♦ De-energising high-voltage system:

Re-energising high-voltage system

2. General information on air conditioning systems 31

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
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DANGER!

High voltage can cause fatal injury.

Note

♦ Re-energising high-voltage system:

Vehicles with start/stop system

WARNING

Injury risk due to automatic engine start (vehicles with start/

All vehicles
♦ General notes ⇒ page 33
♦ Cleaning refrigerant circuit ⇒ page 33
♦ Additionally for vehicles with air conditioner compressor with
no magnetic clutch (with air conditioner compressor regulating
valve - N280- ) ⇒ page 34

32 Rep. gr.87 - Air conditioning system

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Air conditioner with refrigerant R134a - Edition 11.2014

♦ O-rings ⇒ page 38
⇒ “2.16.1 General notes”, page 33
⇒ “2.16.2 Cleaning refrigerant circuit”, page 33
⇒ “2.16.3 Additionally for vehicles with air conditioner compressor
without magnetic clutch (with air conditioner compressor regulat‐
ing valve N280 only)”, page 34
⇒ “2.16.4 Additional information on vehicles with high-voltage
system”, page 34
⇒ “2.16.5 O-rings”, page 38

2.16.1 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 workshop extraction systems, if available.
• 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 294 .
♦ Do not top up refrigerant in circuit; discharge existing refriger‐
ant and re-charge system.

2.16.2 Cleaning refrigerant circuit

The refrigerant circuit must be cleaned (flushed) with refrigerant
R134a ⇒ page 116 (or blown out with compressed air and nitro‐
gen ⇒ page 108 ) 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)

2. General information on air conditioning systems 33

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Air conditioner with refrigerant R134a - Edition 11.2014

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).

2.16.3 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.

2.16.4 Additional information on vehicles with

high-voltage system
Hybrid vehicles
For all work on vehicles with a high-voltage system, note the ad‐
ditional warning instructions for working on such vehicles
⇒ “1 Warning instructions when working on vehicles with high-
voltage system”, page 1 and ⇒ Electrical system; Rep. gr. 93 ;
General warning instructions for work on the high-voltage sys‐
tem .

WARNING

Safety hazard: the engine can start unexpectedly.

Before carrying out general work on a vehicle with high-voltage
electrical system, switch off the ignition and remove the ignition
key from the vehicle.

WARNING

Working on vehicles with high-voltage wiring:

34 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

DANGER!

Risk of fatal injury if high-voltage components are damaged.

If work is necessary in the vicinity of high-voltage system com‐

2. General information on air conditioning systems 35

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

DANGER!

High voltage can cause fatal injury.

Note

♦ De-energising high-voltage system:

Re-energising high-voltage system

36 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

DANGER!

High voltage can cause fatal injury.

Note

♦ Re-energising 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 by way of the “Compressor run-in” function of the
basic setting routine. Otherwise, the air conditioner compres‐
sor may be damaged if refrigerant oil has accumulated in the
compression chamber of the air conditioner compressor due
to inappropriate storage prior to installation. ⇒ Vehicle diag‐
nostic tester 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
in “Guided Fault Finding” mode for air conditioner and battery
regulation .

2. General information on air conditioning systems 37

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
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DANGER!

When working on a vehicle with the ignition switched on or

– To minimise the number of automatic engine starts with

READY active during checking and measurement work, the
vehicle batteries must be charged, e.g. with the Battery charg‐
er, 60A - VAS 5904- in battery back-up mode ⇒ Electrical
system; Rep. gr. 27 and ⇒ Electrical system; Rep. gr. 93 ;
General warning instructions for work on the high-voltage sys‐
tem .
– For test and measurement work that requires the vehicle's
drive system to be active (READY) or the ignition to be switch‐
ed on, move the selector lever to position “P”, activate the
parking brake and take care to keep well clear of the engine
when it is running. Set up any tools needed so that they cannot
come into contact with moving parts.

2.16.5 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; System overview - Refrigerant circuit (ve‐
hicle-specific Workshop Manual).
♦ Seals may only be used once.
♦ Before fitting, lightly lubricate seals with refrigerant oil (PAG
oil).

2.17 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 106 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 106

38 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

– 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 106 and ⇒ Vehicle diagnostic tester, “Guided Fault
Finding” function for air conditioner and battery regulation

2. General information on air conditioning systems 39

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
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3 General information on refrigerant

circuit
Vehicles with high-voltage system (hybrid vehicles)
For all work on vehicles with a high-voltage system, note the ad‐
ditional warning instructions for working on such vehicles
⇒ “1 Warning instructions when working on vehicles with high-
voltage system”, page 1 and ⇒ Electrical system; Rep. gr. 93 ;
General warning instructions for work on the high-voltage sys‐
tem .

WARNING

Safety hazard: the engine can start unexpectedly.

Before carrying out general work on a vehicle with high-voltage
electrical system, switch off the ignition and remove the ignition
key from the vehicle.

WARNING

Working on vehicles with high-voltage wiring:

40 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

DANGER!

Risk of fatal injury if high-voltage components are damaged.

If work is necessary in the vicinity of high-voltage system com‐

3. General information on refrigerant circuit 41

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

DANGER!

High voltage can cause fatal injury.

Note

♦ De-energising high-voltage system:

Re-energising high-voltage system

42 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

DANGER!

High voltage can cause fatal injury.

Note

♦ Re-energising high-voltage system:

Vehicles with start/stop system

WARNING

Injury risk due to automatic engine start (vehicles with start/

3. General information on refrigerant circuit 43

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

All vehicles
⇒ “3.1 Components of refrigerant circuit”, page 44
⇒ “3.2 Layout of components of refrigerant circuit and their influ‐
ence on high-pressure and low-pressure sides”, page 44
⇒ “3.3 Design of refrigerant circuit”, page 64
⇒ “3.5 Connections for quick-release coupling in refrigerant cir‐
cuit”, page 68
⇒ “3.6 Switches and senders in refrigerant circuit and related
connections ”, page 71
⇒ “3.7 Electrical components not installed in refrigerant circuit”,
page 77
⇒ “3.8 Pressures and temperatures in refrigerant circuit”,
page 77
⇒ “3.9 Tests and measurements performed with pressure gauge”,
page 82
⇒ “3.10 Air conditioner service and recycling units”, page 83
⇒ “3.11 Repair notes for refrigerant circuit”, page 84

3.1 Components of refrigerant circuit

Caution

Tools or materials (e.g. sealing additives) that have not been

• 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 270 .

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. Conse‐
quently, no or only very slight pressure equalisation is perceptible
on unscrewing the sealing plugs from the replacement part.

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.
High pressure results from the restrictor or expansion valve form‐
ing a constriction and causing the refrigerant to accumulate, 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‐

44 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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. General information on refrigerant circuit 45

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

⇒ “3.2.1 Mechanically driven air conditioner compressor”,

page 46
⇒ “3.2.2 Electrically driven air conditioner compressor for vehicles
with a high-voltage system”, page 47
⇒ “3.2.3 Condenser”, page 54
⇒ “3.2.4 Evaporator”, page 54
⇒ “3.2.5 Reservoir”, page 55
⇒ “3.2.6 Restrictor”, page 56
⇒ “3.2.7 Receiver”, page 57
⇒ “3.2.8 Expansion valve”, page 58
⇒ “3.2.9 Expansion valve with refrigerant shut-off valve 2 for hy‐
brid battery N517 ”, page 59
⇒ “3.2.10 Shut-off valves for refrigerant”, page 59
⇒ “3.2.11 Refrigerant line with internal heat exchanger”,
page 60
⇒ “3.2.12 Quick-release couplings on refrigerant line”,
page 61
⇒ “3.2.13 O-rings”, page 62
⇒ “3.2.14 Pipes and hoses of refrigerant circuit”, page 62
⇒ “3.2.15 High-pressure safety valve”, page 63

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 sys‐
tem 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.

46 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

♦ The air conditioner compressor contains refrigerant oil which

mixes with refrigerant R134a at all temperatures.
♦ The rating 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,
the high-pressure side of the air conditioner compressor may
be fitted with a valve to prevent the backflow of liquid refriger‐
ant into the compressor after switching off the air conditioning
system. If an air conditioner compressor with this valve is fitted
on a vehicle with a refrigerant circuit with an expansion valve,
a relatively long period may elapse before the pressure on the
high-pressure side decreases (the expansion valve is cold and
the pressure on the low-pressure side increases rapidly after
switch-off, the expansion valve closes 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 actuated in conjunction with regulating valve
-C- ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant cir‐
cuit; System overview - Refrigerant circuit .

3.2.2 Electrically driven air conditioner com‐

pressor for vehicles with a high-voltage
system
Hybrid vehicles
For all work on vehicles with a high-voltage system, note the ad‐
ditional warning instructions for working on such vehicles
⇒ “1 Warning instructions when working on vehicles with high-
voltage system”, page 1 and ⇒ Electrical system; Rep. gr. 93 ;
General warning instructions for work on the high-voltage sys‐
tem .

3. General information on refrigerant circuit 47

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

WARNING

Safety hazard: the engine can start unexpectedly.

Before carrying out general work on a vehicle with high-voltage
electrical system, switch off the ignition and remove the ignition
key from the vehicle.

WARNING

Working on vehicles with high-voltage wiring:

DANGER!

Risk of fatal injury if high-voltage components are damaged.

48 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

If work is necessary in the vicinity of high-voltage system com‐

DANGER!

High voltage can cause fatal injury.

Note

♦ De-energising high-voltage system:

Re-energising high-voltage system

3. General information on refrigerant circuit 49

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

DANGER!

High voltage can cause fatal injury.

Note

♦ Re-energising high-voltage system:

DANGER!

When working on a vehicle with the ignition switched on or

– To minimise the number of automatic engine starts with

READY active during checking and measurement work, the
vehicle batteries must be charged, e.g. with the Battery charg‐

50 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

er, 60A - VAS 5904- in battery back-up mode ⇒ Electrical

system; Rep. gr. 27 and ⇒ Electrical system; Rep. gr. 93 ;
General warning instructions for work on the high-voltage sys‐
tem .

3. General information on refrigerant circuit 51

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

– 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.
Electrically driven air conditioner compressor

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 into the air conditioner compressor regulates the speed
and thus the output of the air conditioner compressor ( elec‐
trical air conditioner compressor - V470- ) on the basis of the
request 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 from 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 ; Repair set VAS 6410 .

52 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 rating 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 has an internal oil circuit to
ensure that the air conditioner compressor is not damaged
when the refrigerant circuit is empty. This means that ap‐
prox. 40 to 50 cm3 of refrigerant oil remains in the air condi‐
tioner 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
Finding” function 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 by way of the “Compressor run-in” function of the
basic setting routine. Otherwise, the air conditioner compres‐
sor may be damaged if refrigerant oil has accumulated in the
compression chamber of the air conditioner compressor due
to inappropriate storage prior to installation ⇒ Vehicle diag‐
nostic tester 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
in “Guided Fault Finding” mode for air conditioner and battery
regulation .

3. General information on refrigerant circuit 53

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

3.2.3 Condenser
The condenser transfers heat from the compressed refrigerant
gas to the surrounding air.
In this process, the refrigerant gas condenses to form 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; System overview - 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 294 and ⇒ Electronic
parts catalogue .

3.2.4 Evaporator
Evaporators come in different versions. Depending on the struc‐
ture and function, the thermal energy required to evaporate the
refrigerant 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
evaporator (e.g. in the case of the heat exchanger for high-voltage
battery) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit; System overview - Refrigerant circuit (vehicle-specific
workshop manual).

Note

Two versions of an evaporator are described below.

54 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 drawn in by the air conditioner compressor together with
the heat absorbed.
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 down, the re‐
frigerant evaporates and is drawn into the air conditioner com‐
pressor carrying with it the heat it has absorbed.
A defined quantity of refrigerant is supplied to the evaporator by
way of a restrictor (or an expansion valve) and a shut-off valve.
The flow rate of the refrigerant (or coolant) is regulated in such a
way that the refrigerant emerging from the evaporator outlet is in
gaseous form ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
erant circuit; System overview - Refrigerant circuit (vehicle-spe‐
cific workshop manual).

3.2.5 Reservoir
To ensure that the air conditioner compressor draws in only gas‐
eous refrigerant, the reservoir collects the mixture of vapour and
gas coming from the evaporator. The vapour becomes gaseous
refrigerant.
Refrigerant oil entrained in the circuit does not remain in the res‐
ervoir as an oil extraction bore is provided.
Any moisture ingressing into the refrigerant circuit during assem‐
bly 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 ingressed, or if renewal
is stipulated due to a specific complaint ⇒ page 270 .
♦ Do not remove the sealing plugs -A- and -B- until immediately
prior to installation.
♦ If the reservoir is not sealed, the desiccant bag soon becomes
saturated with moisture and thus unusable.
♦ When installing, observe arrow indicating direction of flow (if
applicable).

3. General information on refrigerant circuit 55

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

3.2.6 Restrictor
Restrictor upstream of the evaporator
The restrictor creates a constriction. This restriction limits the flow,
separating the high-pressure and low-pressure sides in the re‐
frigerant circuit. Upstream of the restrictor, the refrigerant is warm
due to the high pressure. Downstream of the restrictor, the refrig‐
erant is cold due to the low pressure. Upstream of the narrow point
is a strainer to catch dirt and downstream of the narrow point is a
strainer 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; System overview - Refrigerant cir‐
cuit (vehicle-specific Workshop Manual) and ⇒ Electronic
parts catalogue .

Restrictor upstream of heat exchanger for high-voltage battery

(chiller)

The restrictor creates a constriction. This restriction limits the flow,

separating the high-pressure and low-pressure sides in the re‐
frigerant circuit. Upstream of the restrictor, the refrigerant is warm
due to the high pressure. Downstream of the restrictor, the refrig‐
erant 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.
gr. 87 ; Refrigerant circuit; System overview - Refrigerant cir‐
cuit (vehicle-specific Workshop Manual) and ⇒ Electronic
parts catalogue .

56 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

3.2.7 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 ingressed, or if renewal is
stipulated due to a specific complaint ⇒ page 270 .
♦ Do not remove the sealing plugs until immediately prior to in‐
stallation.
♦ 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; System overview - Refrigerant circuit (vehicle-
specific Workshop Manual) and ⇒ Electronic 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 or ⇒ Air conditioning;
Rep. gr. 87 (vehicle-specific Workshop Manual) and ⇒ Elec‐
tronic 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; System overview - Refrigerant circuit (vehicle-
specific Workshop Manual) and ⇒ Electronic parts catalogue .

3. General information on refrigerant circuit 57

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

3.2.8 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
circuit; System overview - Refrigerant circuit (vehicle-specific
Workshop Manual) and ⇒ Electronic parts catalogue .
♦ Depending on the version of the air conditioner compressor,
the high-pressure side of the air conditioner compressor may
be fitted with a valve to prevent the backflow of liquid refriger‐
ant into the compressor after switching off the air conditioning
system. If an air conditioner compressor with this valve is fitted
on a vehicle with a refrigerant circuit with an expansion valve,
a relatively long period may elapse before the pressure on the
high-pressure side decreases (the expansion valve is cold and
the pressure on the low-pressure side increases rapidly after
switch-off, the expansion valve closes 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.

58 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

3.2.9 Expansion valve with refrigerant shut-off

valve 2 for hybrid battery - N517-
♦ 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‐
tuated e.g. by the battery regulation control unit - J840- ⇒ Cur‐
rent flow diagrams, Electrical fault finding and Fitting locations
and ⇒ Vehicle diagnostic tester in “Guided Fault Finding”
mode 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 .

3.2.10 Shut-off valves for refrigerant

Different designations, depending on the function and vehicle ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System
overview - Refrigerant circuit (vehicle-specific Workshop Man‐
ual).
♦ Shut-off valve 1 for refrigerant for hybrid battery - N516- (e.g.
on the Audi Q5 Hybrid)
♦ Refrigerant shut-off valve for heater and air conditioner unit -
N541-
♦ Refrigerant shut-off valve for high-voltage battery heat ex‐
changer - N542-

3. General information on refrigerant circuit 59

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

♦ 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
relevant control unit (e.g. the -J840- on the Audi Q5 Hybrid)
actuates 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 and ⇒ Heat‐
ing, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System
overview - Refrigerant circuit (for the relevant vehicle).

3.2.11 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; System overview - Refrigerant circuit (vehicle-spe‐
cific Workshop Manual).

A - Refrigerant line with internal heat exchanger

B - Channels in the refrigerant line in which the hot liquid refrig‐
erant flows to the evaporator (high-pressure side of the refrigerant
circuit).
C - Channel in the refrigerant line in which the cold refrigerant gas
or vapour flows to the air conditioner compressor (low-pressure
side of the refrigerant circuit).

60 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

3.2.12 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
conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - Refrigerant circuit (vehicle-specific 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 ;
Refrigerant circuit; System overview - Refrigerant circuit (ve‐
hicle-specific Workshop Manual).
♦ 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
circuit; System overview - Refrigerant circuit (vehicle-specific
Workshop Manual) and ⇒ Electronic 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”)

3. General information on refrigerant circuit 61

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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-.

3.2.13 O-rings
These rings seal the joints between the individual components of
the refrigerant circuit.
Only use O-rings resistant to R134a refrigerant and the related
refrigerant oils. This is guaranteed if genuine replacement 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; System over‐
view - Refrigerant circuit (vehicle-specific Workshop Manual)
and ⇒ Electronic parts catalogue .

Note

The colour coding of O-rings for R134a refrigerant circuits has

been discontinued. Use is made of black and coloured O-rings ⇒
Electronic parts catalogue and ⇒ Heating, air conditioning; Rep.
gr. 87 ; Refrigerant circuit; System overview - Refrigerant circuit
(vehicle-specific Workshop Manual).

3.2.14 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.

62 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

3.2.15 High-pressure safety valve

The high-pressure safety valve is fitted to the air conditioner com‐
pressor 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- over 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
refrigerant does not emerge in one direction but is distributed
through the openings -D- under the cover -C-.

3. General information on refrigerant circuit 63

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

3.3 Design of refrigerant circuit

⇒ “3.3.1 Refrigerant circuit with expansion valve and evaporator”,
page 64
⇒ “3.3.2 Refrigerant circuit with restrictor and reservoir”,
page 64
⇒ “3.4 Refrigerant circuit with electrically driven air conditioner
compressor (with and without battery cooling module)”,
page 64

3.3.1 Refrigerant circuit with expansion valve

and evaporator
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
1- Air conditioner compressor
2- Condenser
3- Restrictor
4- Evaporator
5- Reservoir

Note

Arrows show direction of refrigerant flow.

3.4 Refrigerant circuit with electrically driven

air conditioner compressor (with and
without battery cooling module)
Vehicles with high-voltage system (hybrid vehicles)
For all work on vehicles with a high-voltage system, note the ad‐
ditional warning instructions for working on such vehicles
⇒ “1 Warning instructions when working on vehicles with high-
voltage system”, page 1 and ⇒ Electrical system; Rep. gr. 93 ;
General warning instructions for work on the high-voltage sys‐
tem .

64 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

WARNING

Safety hazard: the engine can start unexpectedly.

Before carrying out general work on a vehicle with high-voltage
electrical system, switch off the ignition and remove the ignition
key from the vehicle.

WARNING

Working on vehicles with high-voltage wiring:

DANGER!

Risk of fatal injury if high-voltage components are damaged.

3. General information on refrigerant circuit 65

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

If work is necessary in the vicinity of high-voltage system com‐

DANGER!

High voltage can cause fatal injury.

Note

♦ De-energising high-voltage system:

Re-energising high-voltage system

66 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

DANGER!

High voltage can cause fatal injury.

Note

♦ Re-energising high-voltage system:

Note

The refrigerant circuits have different structures ⇒ Heating, air

conditioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific Workshop Manual). The illus‐
tration below shows a refrigerant circuit as it is installed in the Audi
Q5 Hybrid as an example.

Arrows show direction of refrigerant flow.

3. General information on refrigerant circuit 67

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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-
❑ Vehicles with battery
cooling module for hy‐
brid battery unit - AX1-
only

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
❑ Vehicles with battery cooling module for hybrid battery unit - AX1- only

Note

-N517- is activated if battery needs

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

8 - Evaporator
❑ Evaporator in battery cooling module
❑ Vehicles with battery cooling module for hybrid battery unit - AX1- only
9 - Service connection (low-pressure side)

3.5 Connections for quick-release coupling

in refrigerant circuit
• Only valves and connections resistant to R134a refrigerant
and the related refrigerant oils are to be used.
• There are different connections (outer diameter) for high and
low-pressure sides.

68 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

• 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; System overview - Refrigerant circuit (vehicle-
specific Workshop Manual).

WARNING

Risk of injury (frostbite).

Refrigerant will emerge if the refrigerant circuit has not been
drained.
Extract refrigerant before opening refrigerant circuit. Renewed
evaporation may create pressure in the refrigerant circuit if the
refrigerant circuit is not opened within 10 minutes following ex‐
traction. Extract refrigerant again.

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

page 69
⇒ “3.5.2 Connections with primary sealing valve (ball valve)”,
page 70

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

♦ Following connection, carefully screw the handwheel of the

service coupling into the quick-release coupling adapter to the
extent required to reliably open the valve in the service con‐
nection (observe the pressure gauge; take care not to open
the valve too far).
♦ To remove and install the valve core -B- with the refrigerant
circuit drained, make use of an adapter from the socket -
T10364- for example.
♦ 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‐
tronic parts catalogue .

3. General information on refrigerant circuit 69

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 sealing cap
5- Cap

Note

♦ Following connection, carefully screw the handwheel of the

service coupling into the quick-release coupling adapter to the
extent required to reliably open the valve in the service con‐
nection (observe the pressure gauge; take care not to open
the valve too far).
♦ To remove and install the valve -3- with the refrigerant circuit
drained, make use of an adapter from the socket - T10364- for
example.
♦ There are different versions of these valves (with internal or
external thread) and the tightening torques may therefore also
differ. 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 .

70 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 sealing cap
5- Cap

Note

♦ Carefully screw the handwheel of the service coupling into the

quick-release coupling adapter to the extent required to relia‐
bly open the valve in the service connection (observe the
pressure gauge; take care not to open the valve too far).
♦ To remove and install the valve -3- with the refrigerant circuit
drained, make use of an adapter from the socket - T10364- for
example.
♦ There are different versions of these valves (with internal or
external thread) and the tightening torques may therefore also
differ. 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 .

3.6 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
circuit; System overview - Refrigerant circuit (vehicle-specific
Workshop Manual).

3. General information on refrigerant circuit 71

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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

page 72
⇒ “3.6.2 High-pressure switch for magnetic clutch F118 ”,
page 72
⇒ “3.6.3 Low-pressure switch for air conditioning system F73 ”,
page 73
⇒ “3.6.5 Air conditioning system pressure switch F129 ”,
page 73
⇒ “3.6.6 High-pressure sender G65 and pressure sender for re‐
frigerant circuit G805 ”, page 74
⇒ “3.6.7 Refrigerant pressure and temperature sender G395 ”,
page 75
⇒ “3.6.4 Connections with valve for refrigerant circuit switches”,
page 73
⇒ “3.6.8 Air conditioner compressor regulating valve N280 ”, page
76
⇒ “3.6.9 Air conditioning system compressor speed sender G111
”, page 76
⇒ “3.6.10 Refrigerant temperature sender G454 ”, page 77

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).

72 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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
• There are different threads for switches on the 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

To remove and install the valve core -C- with the refrigerant circuit
drained, make use of an adapter from the socket - T10364- for
example (tightening torque ⇒ page 69 ).

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 air conditioner in the event of excessive pressure
(approx. 32 bar) caused for example by inadequate engine cool‐
ing.
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. General information on refrigerant circuit 73

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 vehicles from a certain version and production date on‐
wards, -G805- replaces -G65- .
♦ One version of the -G65- generates a square-wave signal or
data telegram when voltage is applied. This signal changes
with the pressure in the system. The other version and -G805-
exchange information with the corresponding control unit over
the data bus (e.g. over the “LIN bus”) when voltage is applied
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - Refrigerant circuit (vehicle-specific Work‐
shop Manual).
♦ -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- )
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations.
♦ -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” mode of air conditioner) and ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific Workshop Manual).
♦ -G805- transmits 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 refriger‐
ant circuit and the measured temperature to the connected
control unit. Even if only the pressure signal is evaluated for a
vehicle, a vehicle in which a -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”, ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit; System overview - Refrigerant circuit
(vehicle-specific Workshop Manual).

74 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

3.6.7 Refrigerant pressure and temperature

sender - G395-
The refrigerant pressure and temperature sender - G395- is in‐
stalled instead of the high-pressure sender - G65- or pressure
sender for refrigerant circuit - G805- .
♦ 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” mode of air conditioner) and ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific 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 on account of the design
of -G395- and the installation location from the actual temper‐
ature of the refrigerant in the refrigerant circuit. It is therefore
not evaluated at present by all control units and used for air
conditioner control ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit; System overview - Refrigerant circuit (ve‐
hicle-specific Workshop Manual).
♦ 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” mode and ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - Refrigerant circuit (vehicle-specific Workshop Manual).

3. General information on refrigerant circuit 75

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

3.6.8 Air conditioner compressor regulating

valve - N280-
The regulating valve is installed in the air conditioner compressor.
It is actuated by the operating and display unit for air conditioning
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) ⇒ Heating,
air conditioning; Rep. gr. 87 ; Refrigerant circuit; System overview
- Refrigerant circuit (vehicle-specific workshop manual). The
pressure on the low-pressure side is influenced by the regulating
valve, thus regulating the temperature 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 289 .

3.6.9 Air conditioning system compressor

speed sender - G111-
Inductive sender
The sender pulses (4 per compressor revolution) and the engine
speed enable the operating and display unit for Climatronic air
conditioning 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
conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - Refrigerant circuit (vehicle-specific 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).

76 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 next to
the air conditioner compressor.
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

conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - refrigerant circuit (vehicle-specific 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 compressor if the
temperature increases above the value stored for this pres‐
sure ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit; System overview - Refrigerant circuit (vehicle-specific
Workshop Manual) and ⇒ Vehicle diagnostic tester (“Self-di‐
agnosis” or “Guided Fault Finding” function for the air condi‐
tioner).

3.7 Electrical components not installed in

refrigerant circuit
⇒ “3.7.1 Radiator fan control unit J293 ”, page 77

3.7.1 Radiator fan control unit - J293-

This control unit activates and deactivates the magnetic clutch
and thus the air conditioner compressor. It switches the radiator
fans and calculates the pressure in the refrigerant circuit on ve‐
hicles with a high-pressure sender - G65- . Refer to ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations and ⇒
Heating, air conditioning; Rep. gr. 87 ; Installation location over‐
view - Air conditioning (vehicle-specific 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

3. General information on refrigerant circuit 77

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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- .
For these reasons, the values given in the following table are only
to be taken as a guide. 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 pressure
gauge set measurement connections ⇒ Heating, air conditioning;
Rep. gr. 87 ; Refrigerant circuit; System overview - Refrigerant
circuit (vehicle-specific Workshop Manual).
At 20 °C with the engine not running, the pressure in the refrig‐
erant circuit is 4.7 bar ⇒ page 15 (vapour pressure table).

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.

⇒ “3.8.1 Refrigerant circuit with expansion valve”, page 78

⇒ “3.8.2 Refrigerant circuit with restrictor and reservoir”,
page 80

3.8.1 Refrigerant circuit with expansion valve

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 bar 1)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 ℃
high-pressure sender
-4- Service connection Liquid approx. 14 bar approx. +55 ℃
(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 ℃
valve
and
-8- Air conditioner com‐
pressor (HP side)
-9- Air conditioner com‐ Gas approx. 1.2 bar 1)1 approx. -1 ℃ 2)2
pressor (low-pressure
side)

78 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Component State of refrigerant Pressure (bar) Temperature in degrees

centigrade
-10- Damping chamber Gas approx. 1.2 bar 1)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 however only applies within the output range of
the air conditioner compressor. If the output limits of the air conditioner compressor are exceeded, the pressure will increase
⇒ page 206 .
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 206 .

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 design of the refrigerant circuit, a compo‐
nent with an internal heat exchanger may be fitted (e.g. on the
Audi A4 2008 > and the Audi A5 Coupé 2008 > a refrigerant
line with an internal heat exchanger). In the internal heat ex‐
changer, 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 en‐
hancing the efficiency of the air conditioner ⇒ page 60 .

Arrows show direction of refrigerant flow.

HP – High-pressure side of refrigerant circuit (HD in illustration)
LP – Low-pressure side of refrigerant circuit (ND in illustration)

3. General information on refrigerant circuit 79

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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
❑ Different versions de‐
pending on vehicle
6 - Condenser
7 - High-pressure safety valve
8 - Air conditioner compressor
(high-pressure side)
9 - 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
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- 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

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“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 206 .

Note

On vehicles with air conditioner compressor regulating valve -

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

Arrows show direction of refrigerant flow.

HP – High-pressure side of refrigerant circuit (HD in illustration)
LP – Low-pressure side of refrigerant circuit (ND in illustration)

1 - Air conditioner compressor

(high-pressure side)
2 - Condenser
3 - Restrictor
4 - Evaporator
5 - Reservoir
6 - Air conditioner compressor
(low-pressure side)

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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 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.

In addition to the pressure scale, pressure gauges may have one

or more temperature scales. The scale values for R134a are as‐
signed according to the vapour pressure table. As different re‐
frigerants develop different vapour pressures at the same
temperature, each temperature scale is marked for the
appropriate refrigerant.
⇒ “3.9.1 Pressure gauges permit the following test and measure‐
ment operations”, page 82

3.9.1 Pressure gauges permit the following

test and measurement operations
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 exists in a refrigerant circuit containing
liquid or vapour, but not gas. In the gas state, the temperature is
approx. 10 °C to 30 °C higher than the pressure gauge reading.

Detection of refrigerant in a closed vessel

Refrigerant R134a is present in a closed vessel or in the refrig‐
erant circuit 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.

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Note

The relationship between pressure and temperature indicated on

the pressure gauges no longer applies if no liquid is present and
the pressure is built up solely 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 116 .
⇒ “3.10.1 Classification of extraction systems”, page 83
⇒ “3.10.2 Charging systems that do not require a permit”,
page 84

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. According to §3 Paragraph 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 (by contrast, a permit is required for the system for
filling compressed-gas vessels from these pressure vessels
for transfer to other parties and testing is mandatory).

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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 373 .
• Requires compliance with the basic instructions for use of leak
detectors ⇒ page 177 .
• Requires expert knowledge.

Note

Releasing refrigerant into the environment is prohibited

⇒ page 85 (laws and regulations).

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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 85

4.1 Laws and regulations

Nowadays the effects of climate change can be seen throughout
the world. Climate protection is thus one of the most important
problems to be tackled. Solving this problem does however rep‐
resent 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 the refrigerant R134a on account of the high greenhouse
potential.
A number of laws of relevance to the automobile 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. 2037/2000
♦ Regulation (EC) no. 842/2006
♦ Regulation (EC) no. 706/2007
♦ Regulation (EC) no. 307/2008
♦ 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.
The following is however generally applicable:
Operation, maintenance, shutdown, obligation to accept return
♦ With regard to the operation, repair and shutdown of items
containing refrigerants, it is prohibited to contravene the state
of the art by allowing 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.
♦ Distributors of the substances and preparations listed in the
above-mentioned regulations are obliged to take back such

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substances and preparations after use or to ensure that these

are taken back by a third party appointed 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.
Various technical regulations (e.g. TRGS 400, TRGS 402, TRGS
407, TRGS 510, TRGS 725/TRBS 3145) must be noted when
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 other ergonomic findings for the pro‐
vision and use of work equipment as well as for the operation
of systems requiring supervision and/or for activities involving
hazardous substances.
♦ The specified technical regulations apply to Germany; in other
countries, rules and regulations differing from these may ap‐
ply.

Various technical regulations (e.g. TRGS 400, TRGS 402, TRGS

407, TRGS 510, TRGS 725/TRBS 3145) must be noted when
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.

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♦ 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‐

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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, check the charged
vessels gravimetrically on calibrated scales or volumetrically,
provided that the compressed gases are not highly toxic. Volu‐
metric 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
Transfer refrigerants intended for disposal to marked recycling
containers, 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 (differ‐
ent regulations and rules may apply in other countries).
Disposal of refrigerant oil
Dispose of used refrigerant oils from systems employing halo‐
genated hydrocarbons as waste requiring special monitoring.
They are not to be mixed with other oils or substances. Proper
storage and disposal must be ensured in line with local regula‐
tions. In Germany, reference should be made for example to the
climate protection regulation on chemicals and the recycling and

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refuse law (different regulations and rules may apply in other

countries) ⇒ Audi-ServiceNet, HSO Environmental Protection .
⇒ “4.1.1 Change-over of an R12 refrigerant circuit to an R134a
refrigerant circuit and servicing (retrofit) ”, page 89
⇒ “4.1.2 Keeping refrigerant records”, page 89

4.1.1 Change-over of an R12 refrigerant cir‐

cuit to an R134a refrigerant circuit and
servicing (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.

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5 Refrigerant circuit
⇒ “5.1 Important repair notes for air conditioning systems”,
page 90
⇒ “5.2 Converting refrigerant circuits from refrigerant R12 to re‐
frigerant R134a ”, page 90
⇒ “5.3 Working with the air conditioner service station”,
page 90
⇒ “5.4 Blowing out refrigerant circuit with compressed air and ni‐
trogen ”, page 108
⇒ “5.5 Cleaning (flushing) refrigerant circuit with refrigerant
R134a”, page 116
⇒ “5.6 Tracing leaks in refrigerant circuit ”, page 177

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 89 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 labelled,
marked with green stickers or designed (e.g. a different
thread) so that interchange with components for refrigerant
R12 is not possible.
• The refrigerant being used is indicated by a label affixed to the
lock carrier in the engine compartment or in the plenum cham‐
ber.
• Never mix various refrigerants.

Note

When working on the refrigerant circuit, always pay attention the

information given in the Sections on “Safety measures”
⇒ page 24 and “Basic rules for working on refrigerant circuit”
⇒ page 29 .

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 hardcopy form).

5.3 Working with the air conditioner service

station
Vehicles with high-voltage system (hybrid vehicles)
For all work on vehicles with a high-voltage system, note the ad‐
ditional warning instructions for working on such vehicles

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⇒ “1 Warning instructions when working on vehicles with high-

voltage system”, page 1 and ⇒ Electrical system; Rep. gr. 93 ;
General warning instructions for work on the high-voltage sys‐
tem .

WARNING

Safety hazard: the engine can start unexpectedly.

Before carrying out general work on a vehicle with high-voltage
electrical system, switch off the ignition and remove the ignition
key from the vehicle.

WARNING

Working on vehicles with high-voltage wiring:

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DANGER!

Risk of fatal injury if high-voltage components are damaged.

If work is necessary in the vicinity of high-voltage system com‐

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.

De-energising high-voltage system

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DANGER!

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock.
♦ The high-voltage system may only be de-energised by a
suitably qualified person (Audi high-voltage technician).
♦ It must be definitely confirmed that the high-voltage sys‐
tem is de-energised. The system may only be de-ener‐
gised using the vehicle diagnostic tester via “Guided Fault
Finding”.
♦ The qualified person (Audi high-voltage technician) en‐
sures that the system is de-energised and secured with
the locking cap - T40262- to prevent anyone from switch‐
ing it on. Furthermore, the qualified person must also store
the ignition key and maintenance connector for high-volt‐
age system - TW - in a safe place as an additional meas‐
ure to prevent the system from being switched back on.
♦ The qualified person (Audi high-voltage technician) marks
the vehicle by attaching the appropriate warning signs.

Note

♦ De-energising high-voltage system:

Re-energising high-voltage system

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DANGER!

High voltage can cause fatal injury.

Note

♦ Re-energising high-voltage system:

DANGER!

When working on a vehicle with the ignition switched on or

– 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

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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 .
– For test and measurement work that requires the vehicle's
drive system to be active (READY) or the ignition to be switch‐
ed on, move the selector lever to position “P”, activate the
parking brake and take care to keep well clear of the engine
when it is running. Set up any tools needed so that they cannot
come into contact with moving parts.

Note

♦ 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.
♦ The status of the drive system (READY) is shown by the con‐
trol unit in dash panel insert - J285- via the “power meter” ⇒
Owner's Manual .
♦ Activating and deactivating drive system ⇒ Owner's Manual
(note display of control unit in dash panel insert - J285- ).

Vehicles with start/stop system

WARNING

Injury risk due to automatic engine start (vehicles with start/

All vehicles

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 95
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 does not permit the use of chemical substances (sealing
additives) to seal leaks in the refrigerant circuit.
♦ 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) for sealing leaks in
the refrigerant circuit are normally not outwardly apparent and
the identification stickers which should be affixed are usually
non-existent. Vehicles with an unknown history should there‐
fore be treated with due caution.
♦ 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 end of the vehicle refrigerant circuit (the air con‐
ditioner service station is not to be attached to the service
connection on the high-pressure end 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 renewed 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 even if this is just strongly suspected), inform the cus‐
tomer (vehicle owner) of the following:
♦ The air conditioner refrigerant cannot be extracted on account
of the substances added (sealing additives), as these could

96 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 conditioner can only be properly repaired by renewing
all the refrigerant circuit components which have come into
contact with the sealing additive. The sealing additive may al‐
ready have damaged certain refrigerant circuit components
(e.g. the air conditioner compressor regulating valve - N280- )
or lead to damage and subsequent failure shortly after re‐
newed start-up. Furthermore, sealing additive deposits may
subsequently work loose in the refrigerant circuit components
and then lead to renewed failure of the air conditioner (com‐
plete cleaning of these components with workshop equipment
is not possible at present).
Work on the air conditioner refrigerant circuit
⇒ “5.3.1 Important notes for working with the air conditioner serv‐
ice station”, page 97
⇒ “5.3.2 Connecting air conditioner service station for measuring
and testing”, page 98
⇒ “5.3.3 Discharging refrigerant circuit with air conditioner service
station”, page 99
⇒ “5.3.4 Evacuating refrigerant circuit with air conditioner service
station”, page 101
⇒ “5.3.5 Charging refrigerant circuit with air conditioner service
station”, page 105
⇒ “5.3.6 Starting up air conditioner after charging”, page 106
⇒ “5.3.7 Pouring refrigerant into reservoir (charging cylinder or
storage vessel) of air conditioner service station”, page 107
⇒ “5.3.8 Discharging air conditioner service station”, page 108

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 at the latest when
the operational time specified in the related operating instruc‐
tions 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 108 .
– Use is only to be made of refrigerant oils which are also ap‐
proved for the vehicle-specific refrigerant circuit (if applicable,
add the refrigerant 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, drain the air conditioner service station
⇒ page 198 , 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 con‐

5. Refrigerant circuit 97
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

tainers for recycling or ecological disposal (other or additional

regulations may apply in other 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 containers (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.

To prevent air or moisture entering the refrigerant circuit through

the charging hoses, connect hoses as follows:
– Switch off ignition.
– Connect air conditioner service station to power supply.
– Unscrew the sealing caps from the service connections or the
connections with valve (refer to vehicle-specific refrigerant cir‐
cuit) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit; System overview - Refrigerant circuit (vehicle-specific
Workshop Manual).
– Evacuate the charging 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 side

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 sides 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 206 .
– Before detaching the quick-release coupling, close it by screw‐
ing out the handwheel.

98 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Vehicles with one service connection only:

Note

Screw the valve adapters - V.A.G 1785/9- , -V.A.G 1785/10- or

the adapter set - V.A.G 1786- to the refrigerant circuit connections
with valve and bleed the charging hoses during connection to the
adapters (only a faintly audible escape of refrigerant gas is per‐
mitted) ⇒ page 198 .

– The charging hose must be fitted with a valve opener to open

the valve in the valve adapter.

5.3.3 Discharging refrigerant circuit with air

conditioner service station
• 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:
– Switch off ignition.
– Connect the air conditioner service station in line with the op‐
erating instructions to the vehicle service connections (refer to
vehicle-specific refrigerant circuit) and start up the service sta‐
tion ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit; System overview - Refrigerant circuit (vehicle-specific
Workshop Manual).
– 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.

5. Refrigerant circuit 99
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

WARNING

Risk of injury (frostbite).

Refrigerant may emerge if the refrigerant circuit has not been
drained.
Extract refrigerant before opening refrigerant circuit. Renewed
evaporation may create pressure in the refrigerant circuit if the
refrigerant circuit is not opened within 10 minutes following ex‐
traction. Extract refrigerant again.

Note

♦ There is a possibility of refrigerant oil being extracted from the

refrigerant circuit together with the refrigerant. To ensure air
conditioner compressor lubrication, the refrigerant oil in the
circuit must be topped up with fresh oil ⇒ page 294 .
♦ On vehicles fitted with an air conditioner compressor with no
magnetic clutch (with an air conditioner compressor regulating
valve - N280- ), do not run the engine for longer than absolutely
necessary with the refrigerant circuit empty, and avoid high
engine speeds (constant air conditioner compressor opera‐
tion).
♦ On vehicles with an air conditioner compressor with no mag‐
netic clutch, the engine is only to be started following complete
assembly of the refrigerant circuit (avoid high engine speeds).
♦ Depending on the version of the air conditioner compressor,
the high-pressure side of the air conditioner compressor may
be fitted with a valve to prevent the backflow of liquid refriger‐
ant into the compressor after switching off the air conditioning
system. If an air conditioner compressor with this valve is fitted
on a vehicle with a refrigerant circuit with an expansion valve,
a relatively long period may elapse before the pressure on the
high-pressure side decreases (the expansion valve is cold and
the pressure on the low-pressure side increases rapidly after
switch-off, the expansion valve closes and the refrigerant can
only flow slowly to the low-pressure side). If the air conditioner
compressor is switched on (or the refrigerant circuit is dis‐
charged via the low-pressure side), the pressure on the low-
pressure side decreases, the expansion valve opens 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, after drainage, the refrigerant circuit is to be evacuated and re-
charged, refer to ⇒ page 105 .

100 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

5.3.4 Evacuating refrigerant circuit with air

conditioner service station
• 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 294 .
• Quantity of refrigerant in air conditioner service station
checked
The refrigerant circuit must be evacuated before it is filled with
refrigerant. In addition, moisture is removed 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.

– Switch off ignition.

– Connect air conditioner service station to power supply.
– Connect the charging hoses of the air conditioner service sta‐
tion to the vehicle refrigerant circuit with quick-release cou‐
pling adapters (refer to vehicle-specific refrigerant circuit) ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - Refrigerant circuit (vehicle-specific Work‐
shop 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 198 .

– Switch on air conditioner service station and evacuate refrig‐

erant circuit for at least 30 minutes. In this process, the pres‐
sure reading must be less than 10 mbar absolute (correspond‐
ing 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.

5. Refrigerant circuit 101

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

– Switch off the 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. Charging can only be performed once the
vacuum is maintained.
– It 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:

102 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

5. Refrigerant circuit 103

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 108 . If the leak is of
sufficient magnitude, the leakage location will be revealed by
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 for example a modified charging hose -A- (e.g. with a
5/8"-18 UNF thread, depending on the thread at the quick-re‐
lease coupling adapter) and an appropriate adapter -B-
⇒ page 379 . To prevent the ingress of moisture, oil and dirt
from the workshop compressed air system into the air condi‐
tioner refrigerant circuit, additional use is to be made for ex‐
ample of a combined fine filter unit for compressed air systems
(oil, dirt and water separator as used for painting facilities),
which is to be fitted between the compressed air system and
the charging 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 378 with a charging 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.
♦ Always work with pressure reducers 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 again and observe the vacuum display over a period
of hours. Charging can only be performed once the 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.

104 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

– Pour 100 g of refrigerant into the circuit and use an electronic

leak detector to locate and eliminate any leak ⇒ page 183 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 184 .
– Discharge the refrigerant circuit if necessary ⇒ page 99 .
– Evacuate the refrigerant circuit and observe the vacuum dis‐
play again over a period of hours. Charging can only be
performed once the vacuum is maintained.

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 294 .

• The work procedure must always be performed as described

in the operating instructions of the air conditioner service sta‐
tion.
• Before pouring in refrigerant, correct the quantity of refrigerant
oil ⇒ page 294 .
• 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 filling accuracy of the air conditioner
service station may vary.
– Switch off ignition.
– Evacuate refrigerant circuit with air conditioner service station
⇒ page 101 .
– Turn handwheel of quick-release connector adapters out‐
wards (close).
– Allow refrigerant to flow into filler hose.
– Take the charging cylinder reading.
– Screw in handwheel at quick-release coupling adapter (to
open it) and charge with the specified quantity of refrigerant.
– Switch off air conditioner service station.

5. Refrigerant circuit 105

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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
Finding” function for air conditioner and battery regulation .
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).

106 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Start-up of 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, "Econ"
or A/C off mode (version with no magnetic clutch with a regu‐
lating valve).
– Wait for the idling speed to stabilise.
– Switch on the air conditioner compressor and operate the sys‐
tem for at least 2 minutes at idling speed.
– If necessary, check the pressures in the refrigerant circuit with
the air conditioner service station.
– Switch off engine.
– Screw out the handwheel on the quick-release coupling adapt‐
er.
– Detach the charging hoses from the refrigerant circuit.
– Screw the sealing caps back on.
Start-up of air conditioner with electrically driven air conditioner
compressor
– Start the air conditioner compressor using the Guided Fault
Finding “Basic setting, compressor run-in” function ⇒ Vehicle
diagnostic tester function “Guided Fault Finding” for air condi‐
tioner and battery control .
– If necessary, check the pressures in the refrigerant circuit with
the air conditioner service station on completion of basic set‐
ting.
– Screw out the handwheel on the quick-release coupling adapt‐
er.
– Detach the charging hoses from the refrigerant circuit.
– Screw the sealing caps back on.

5.3.7 Pouring refrigerant into reservoir (charg‐

ing cylinder or storage vessel) of air con‐
ditioner service station
• The work procedure must always be performed as described
in the operating instructions of the air conditioner service sta‐
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).

5. Refrigerant circuit 107

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 drain the air conditioner service station (e.g.

due to extraction of contaminated refrigerant), all filters and
dryers must always be renewed (do not remove filter and dryer
from the air-tight packaging until immediately before installa‐
tion to minimise moisture absorption).
♦ Refrigerant containers filled with contaminated used refriger‐
ant are referred to as “Recycling containers”.
♦ Always evacuate recycling containers prior to initial filling with
refrigerant (if there is air in a refrigerant container it is not to
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

♦ When filling recycling containers (compressed-gas ves‐

sels), observe the applicable regulations, technical rules
and laws.
♦ Recycling containers must never be overfilled. The gas
cushion in overfilled recycling containers is not sufficient
to absorb the liquid expansion caused by the influence of
heat. There is a risk of rupturing.
♦ To ensure safety, make exclusive use of recycling con‐
tainers fitted with a safety valve.
♦ Recycling containers must be weighed on calibrated
scales during the filling process. The maximum permissi‐
ble capacity is 75 % (charge factor 0.75) of the charge
weight indicated on the recycling container (the possibility
of refrigerant oil entering the recycling container along with
the refrigerant cannot be ruled out).

5.4 Blowing out refrigerant circuit with com‐

pressed air and nitrogen
Vehicles with high-voltage system (hybrid vehicles)
For all work on vehicles with a high-voltage system, note the ad‐
ditional warning instructions for working on such vehicles
⇒ “1 Warning instructions when working on vehicles with high-
voltage system”, page 1 and ⇒ Electrical system; Rep. gr. 93 ;
General warning instructions for work on the high-voltage sys‐
tem .

108 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

WARNING

Safety hazard: the engine can start unexpectedly.

Before carrying out general work on a vehicle with high-voltage
electrical system, switch off the ignition and remove the ignition
key from the vehicle.

WARNING

Working on vehicles with high-voltage wiring:

DANGER!

Risk of fatal injury if high-voltage components are damaged.

5. Refrigerant circuit 109

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

If work is necessary in the vicinity of high-voltage system com‐

DANGER!

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock.
♦ The high-voltage system may only be de-energised by a
suitably qualified person (Audi high-voltage technician).
♦ It must be definitely confirmed that the high-voltage sys‐
tem is de-energised. The system may only be de-ener‐
gised using the vehicle diagnostic tester via “Guided Fault
Finding”.
♦ The qualified person (Audi high-voltage technician) en‐
sures that the system is de-energised and secured with
the locking cap - T40262- to prevent anyone from switch‐
ing it on. Furthermore, the qualified person must also store
the ignition key and maintenance connector for high-volt‐
age system - TW - in a safe place as an additional meas‐
ure to prevent the system from being switched back on.
♦ The qualified person (Audi high-voltage technician) marks
the vehicle by attaching the appropriate warning signs.

Note

♦ De-energising high-voltage system:

Re-energising high-voltage system

110 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

DANGER!

High voltage can cause fatal injury.

Note

♦ Re-energising high-voltage system:

DANGER!

When working on a vehicle with the ignition switched on or

– 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

5. Refrigerant circuit 111

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

charger 60A - VAS 5904- in battery standby mode ⇒ Electrical

Note

All vehicles
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 116 .
♦ 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).

112 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 the 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 198 .
Observe the following to prevent oil and moisture from the com‐
pressed-air system from ingressing into the refrigerant circuit.
– The compressed air must be passed through a compressed-
air purifier for cleaning and drying. Use is therefore to be made
of filter and dryer for compressed air (included in scope of de‐
livery as tool for painting work).
– For refrigerant lines with a thread or union nut at the connec‐
tion, make use of adapters from the adapter set for refrigerant
circuit - V.A.G 1785- ( adapter - V.A.G 1785/1- to adapter -
V.A.G 1785/8- ) for connection of the 5/8" -18 UNF charging
hoses (some of these adapters are also contained in the VW/
Audi passenger vehicle adapter set - VAS 6338/1- ).
– For refrigerant pipes 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.

5. Refrigerant circuit 113

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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).
♦ Draw off compressed air/nitrogen emerging from the compo‐
nents using an appropriate system (e.g. workshop extraction
system).

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 the vacuum reading is not maintained on evacuating a leak-
free refrigerant circuit (pressure build-up due to moisture in
refrigerant 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 the likelihood of moisture.
– If there are doubts about the amount of refrigerant oil 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 electric air conditioning compres‐
sor - V470- (damage to the electronic system of the air conditioner
compressor does not always mean that the refrigerant circuit has
to be cleaned) ⇒ page 278

– 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 116 .

114 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

⇒ “5.4.1 Blowing out refrigerant circuit”, page 115

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, for
example, a blow-out gun with rubber mouthpiece or an adapter
from the VW/Audi passenger vehicle adapter set - VAS
6338/1- to blow out the individual components. Special care
must be taken not to damage the connections (crushing or
scratching) when using a blow-out gun with rubber mouth‐
piece.
♦ Blow out the evaporator via the connection for the low-pres‐
sure line (large diameter) after detaching the expansion valve
or removing the 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 is to 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; System overview - refrigerant circuit (vehicle-
specific Workshop Manual).
♦ 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.

After blowing out the 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
circuit; System overview - Refrigerant circuit (vehicle-specific
Workshop Manual) and ⇒ Electronic parts catalogue
– Depending on the problem, renew the air conditioner com‐
pressor ⇒ Heating, air conditioning; Rep. gr. 87 ; Air condi‐
tioner compressor (vehicle-specific Workshop Manual) and ⇒
Electronic parts catalogue , or drain off the remaining refrig‐
erant oil from the air conditioner compressor (removed earlier)
⇒ page 270 (Renewing components of refrigerant circuit) and
add the specified quantity of new refrigerant oil again
⇒ page 332 (Approved refrigerant oils and refrigerant oil ca‐
pacities).

5. Refrigerant circuit 115

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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; System overview - Refrigerant circuit (vehicle-
specific Workshop Manual) and ⇒ page 332 (Approved
refrigerant oils and refrigerant oil capacities).
♦ If the air conditioner compressor is not to be renewed, the re‐
frigerant oil quantity in the air conditioner compressor must be
topped up in line with the specified capacity (pour out refrig‐
erant oil and add the specified quantity to the air conditioner
compressor or the refrigerant circuit again) ⇒ page 270 (Re‐
newing refrigerant circuit components) and ⇒ page 332 (Ap‐
proved refrigerant oils and refrigerant oil capacities).

– Completely re-assemble the refrigerant circuit ⇒ Heating, air

conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - Refrigerant circuit (vehicle-specific Workshop Manual).
– Evacuate and charge the refrigerant circuit as specified
⇒ page 101 and ⇒ page 105 .
– Start up the air conditioner as specified ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrigerant circuit; Operating the air
conditioning after filling the refrigerant circuit (vehicle-specific
Workshop Manual) and ⇒ page 106

5.5 Cleaning (flushing) refrigerant circuit

with refrigerant R134a
Vehicles with high-voltage system (hybrid vehicles)
For all work on vehicles with a high-voltage system, note the ad‐
ditional warning instructions for working on such vehicles
⇒ “1 Warning instructions when working on vehicles with high-
voltage system”, page 1 and ⇒ Electrical system; Rep. gr. 93 ;
General warning instructions for work on the high-voltage sys‐
tem .

WARNING

Safety hazard: the engine can start unexpectedly.

Before carrying out general work on a vehicle with high-voltage
electrical system, switch off the ignition and remove the ignition
key from the vehicle.

116 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

WARNING

Working on vehicles with high-voltage wiring:

DANGER!

Risk of fatal injury if high-voltage components are damaged.

If work is necessary in the vicinity of high-voltage system com‐

5. Refrigerant circuit 117

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

system; Rep. gr. 93 ; General warning instructions for work on

the high-voltage system .
De-energising high-voltage system

DANGER!

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock.
♦ The high-voltage system may only be de-energised by a
suitably qualified person (Audi high-voltage technician).
♦ It must be definitely confirmed that the high-voltage sys‐
tem is de-energised. The system may only be de-ener‐
gised using the vehicle diagnostic tester via “Guided Fault
Finding”.
♦ The qualified person (Audi high-voltage technician) en‐
sures that the system is de-energised and secured with
the locking cap - T40262- to prevent anyone from switch‐
ing it on. Furthermore, the qualified person must also store
the ignition key and maintenance connector for high-volt‐
age system - TW - in a safe place as an additional meas‐
ure to prevent the system from being switched back on.
♦ The qualified person (Audi high-voltage technician) marks
the vehicle by attaching the appropriate warning signs.

Note

♦ De-energising high-voltage system:

Re-energising high-voltage system

118 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

DANGER!

High voltage can cause fatal injury.

Note

♦ Re-energising high-voltage system:

DANGER!

When working on a vehicle with the ignition switched on or

– 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

5. Refrigerant circuit 119

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

charger 60A - VAS 5904- in battery standby mode ⇒ Electrical

Note

All vehicles

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.

120 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

♦ Audi does not permit the use of chemical substances (sealing

additives) to seal leaks in the refrigerant circuit.
♦ 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). The refrigerant circuit can there‐
fore only be repaired by renewing all the components which
have come into contact with this substance.
♦ Chemical substances (sealing additives) for sealing leaks in
the refrigerant circuit are normally not outwardly apparent and
the identification stickers which should be affixed for this pur‐
pose are usually non-existent. 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.
Flush refrigerant circuit:
– In 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 nor‐
mally required for repairs (e.g. following an accident).
– If pressure and temperature measurements in the refrigerant
circuit indicate the likelihood of moisture.
– If there are doubts about the amount of refrigerant oil 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 electric air conditioning
compressor - V470- (damage to the electronic system of the
air conditioner compressor does not always mean that the re‐
frigerant circuit has to be cleaned) ⇒ page 278
♦ 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 333 .

– If stipulated by the vehicle-specific Workshop Manual after re‐

newing certain components

5. Refrigerant circuit 121

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Tools required
♦ Air conditioner service station with flushing attachment (these
air conditioner service stations feature the additional function
“Flushing refrigerant circuit” and the necessary flushing at‐
tachment for refrigerant circuits) ⇒ Electronic parts catalogue
(Tools; Workshop equipment/tools; Air conditioning/heating).
♦ VW/Audi passenger vehicle adapter set - VAS 6338/1-
⇒ page 141 and ⇒ Electronic parts catalogue (Tools; Work‐
shop equipment/tools; Air conditioning/heating).

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 127
♦ 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).

Preparation
– Discharge the refrigerant circuit ⇒ page 99 .
– 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 ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - Refrigerant circuit (vehicle-specific Work‐
shop Manual).
– Remove the reservoir (vehicle-specific) and re-connect the
pipes (for this purpose, make use of an adapter and the charg‐
ing hose - VAS 6338/31- from the VW/Audi passenger vehicle
adapter set - VAS 6338/1- ) ⇒ page 141 , ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific Workshop Manual).

Note

It would be possible to flush the reservoir, however on account of

its large internal volume it holds too much liquid refrigerant. On
extracting this refrigerant, the reservoir would ice up severely, the
refrigerant would only evaporate very slowly and the extraction
process would be excessively long.

Vehicle with expansion valve and receiver

122 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

– Remove the receiver (vehicle-specific, not necessary with all

vehicles) and re-connect the pipes (for this purpose, make use
of an adapter and the charging hose - VAS 6338/31- from the
VW/Audi passenger vehicle adapter set - VAS 6338/1- )
⇒ page 141 , ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐
frigerant circuit; System overview - 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)
⇒ page 141 , ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐
frigerant circuit; System overview - Refrigerant circuit (vehicle-
specific Workshop Manual).
♦ 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 141 and ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - Refrigerant circuit (vehicle-specific 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, the condenser is then to be
renewed together with the receiver ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Refrigerant circuit; System overview -
refrigerant circuit and ⇒ Electronic parts catalogue .
♦ 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.

– 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; System overview -
Refrigerant circuit (vehicle-specific Workshop Manual).
– Remove the expansion valve (vehicle-specific) and replace it
with an adapter from the adapter set for refrigerant circuits -
VAS 6338/1- ⇒ page 141 , ⇒ Heating, air conditioning; Rep.
gr. 87 ; Refrigerant circuit; System overview - Refrigerant cir‐
cuit (vehicle-specific Workshop Manual).
– In the case of vehicles with a shut-off valve, remove this valve
and replace it with an adapter (or manual shut-off valve) from
the VW/Audi passenger vehicle adapter set - VAS 6338/1- (or
a drilled-open shut-off valve) ⇒ page 141 , ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - Refrigerant circuit (vehicle-specific Workshop Manual).

Note

If there is no suitable adapter for the expansion valve (or shut-off

valve) in the VW/Audi passenger vehicle adapter set - VAS
6338/1- , the removed expansion valve (or shut-off valve) can also
be drilled open (the old expansion valve generally has to be re‐
newed anyway and is therefore no longer needed).

5. Refrigerant circuit 123

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Caution

♦ Take care not to damage the sealing surfaces at the ex‐

pansion valve (or shut-off valve) when drilling it open.
♦ Otherwise, refrigerant will escape at damaged sealing
surfaces.

Drill open the 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 differing de‐
sign. 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 is to be separated from the circuit of the first evaporator
and flushed in a separate operation ⇒ page 141 and ⇒ Heating,
air conditioning; Rep. gr. 87 ; Refrigerant circuit; System overview
- Refrigerant circuit (vehicle-specific Workshop Manual).

Drill open the shut-off valve.

Note

A shut-off valve must be drilled out, for example, if there is no

shut-off valve - VAS 6338/42- available to flush the coolant circuit.

124 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

– Start by removing solenoid -A- and solenoid valve -B-.

– Drill open the shut-off valve -C- using a suitable bit (bit diam‐
eter e.g. 5.0 mm).
– Remove swarf remnants produced during drilling of the bore
-D- from the shut-off valve -C-.
– Re-install the solenoid valve -B- with the corresponding seal
-E- in the drilled-open shut-off valve -C-.
Flushing
– Check the amount of refrigerant in the air conditioner service
station, it must contain at least 7 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 side) 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 141 .
– Connect the return hose (low-pressure or suction end) of the
air conditioner service station to the outlet of the refrigerant
circuit flushing attachment.
– Connect the inlet of the refrigerant circuit flushing attachment
with an adapter to the high-pressure line to the air conditioner
compressor (line with smaller diameter) ⇒ page 141 .

5. Refrigerant circuit 125

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

♦ The components are always (with the exception of the electric

air conditioner compressor) flushed in the opposite opposite
to the refrigerant flow during air conditioner operation
⇒ page 129 .
♦ When flushing, impurities from the refrigerant circuit ingress
into the refrigerant circuit flushing attachment and the air con‐
ditioner service station, where they are retained in the built-in
filters and dryer. Depending on the nature of the impurities,
renew these components more frequently as specified by the
operating instructions for the air conditioner service station or
the refrigerant circuit flushing attachment.
♦ 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 the air conditioner compressor)
accumulates at the inspection port of the refrigerant circuit
flushing attachment. If applicable, clean this sight glass after
flushing and flush the refrigerant circuit again in one operation
as a check (one operation 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‐
tioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific Workshop Manual).
♦ Adapters for connection of air conditioner service station and
for bridging certain refrigerant circuit components
⇒ page 141 .

– 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).

126 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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
attachment 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 attachment) is
initially evacuated and the refrigerant circuit checked for leaks
Depending 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 side 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 side of the vehicle refrigerant circuit) or
refrigerant is added until the refrigerant circuit and the inspec‐
tion ports of the refrigerant circuit flushing attachment have
been completely filled with liquid refrigerant (depending on the
version of the air conditioner service station, the system de‐
tects 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 attachment may be
switched on for example depending on the version of the air
conditioner service station and the refrigerant circuit flushing
attachment (only if the refrigerant is extracted in gaseous form
from the refrigerant circuit flushing attachment).
♦ After the refrigerant has been extracted, the heater of the re‐
frigerant circuit flushing attachment 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 .

5. Refrigerant circuit 127

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

♦ Following extraction for the third time, the flushing circuit is

evacuated depending on the version of the air conditioner
service station.
– On completion of flushing, check the inspection port(s) of the
refrigerant circuit flushing attachment. If these are contamina‐
ted, they are to be cleaned if necessary in line with the oper‐
ating instructions for the refrigerant circuit flushing attachment
or air conditioner service station. Flushing is then to be per‐
formed again as a check (one operation with a duration of
approx. 30 min. is sufficient) ⇒ Operating instructions for air
conditioner service 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 vehicle-specific components: restrictor
and reservoir, expansion valve and receiver / desiccant car‐
tridge in the receiver ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit; System overview - Refrigerant circuit (ve‐
hicle-specific Workshop Manual) and ⇒ Electronic parts cata‐
logue
– Depending on the problem, renew the air conditioner com‐
pressor ⇒ Heating, air conditioning; Rep. gr. 87 ; Air condi‐
tioner compressor (vehicle-specific Workshop Manual) and ⇒
Electronic parts catalogue , or drain off the remaining refrig‐
erant oil from the air conditioner compressor (removed earlier)
⇒ page 270 (Renewing components of refrigerant circuit) and
add the specified quantity of new refrigerant oil again
⇒ page 332 (Approved refrigerant oils and refrigerant oil ca‐
pacities).

Note

♦ Replacement compressors contain a certain specified quantity

– Completely re-assemble the refrigerant circuit ⇒ Heating, air

128 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

⇒ “5.5.1 Block diagrams for various flushing circuits”, page 129

⇒ “5.5.3 Adapters for connecting flushing circuits”, page 141
⇒ “5.5.2 Flushing electrically driven air conditioner compressor
(removing refrigerant oil)”, page 134

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 side 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).

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 re‐
strictor are connected back together. The line connections to the
reservoir removed are connected together with two adapters and
the charging hose - VAS 6338/31- (from the VW/Audi passenger
vehicle adapter set - VAS 6338/1- ).

5. Refrigerant circuit 129

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

1 - Air conditioner service sta‐

tion
❑ With electronics and a
flushing program, e.g.
Air conditioner service
station with flushing at‐
tachment ⇒ Electronic
parts catalogue (Tools;
Workshop equipment/
tools; Air conditioning/
heating).
❑ If use is made of an air
conditioner service sta‐
tion without a flushing
program, the process
must be carried out
manually (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‐
ditioner service station
❑ From the high-pressure
end of the air condition‐
er service station (gen‐
erally red coloured) to
the connection for the
low-pressure end of the
air conditioner compres‐
sor at the refrigerant cir‐
cuit (larger diameter)
3 - Adapter for connection
(low-pressure side) to refriger‐
ant circuit
❑ Different versions de‐
pending on vehicle
⇒ page 141
❑ From adapter set for refrigerant circuits - VAS 6338/1-
4 - Connection (low-pressure side) at refrigerant circuit
❑ Different versions depending on vehicle ⇒ page 141
❑ At the refrigerant pipe from the air conditioner compressor to the reservoir
5 - Connection to reservoir
❑ Different versions depending on vehicle ⇒ page 141
❑ At the refrigerant pipe from the air conditioner compressor to the reservoir
6 - Adapter for bridging reservoir after removal
❑ Different versions depending on vehicle ⇒ page 141
❑ From adapter set for refrigerant circuits - VAS 6338/1-
7 - Filler hose for refrigerant ⇒ page 141
❑ For example filler hose - VAS 6338/31- (from adapter set for refrigerant circuits - VAS 6338/1- )
8 - Adapter for bridging reservoir after removal
❑ Different versions depending on vehicle ⇒ page 141
❑ From adapter set for refrigerant circuits - VAS 6338/1-
9 - Connection to reservoir
❑ Different versions depending on vehicle ⇒ page 141

130 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

10 - Evaporator
11 - Fitting location for restrictor
❑ Restrictor removed.
❑ Removing restrictor ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific Workshop Manual).
12 - Threaded connection in refrigerant line
❑ Screw back together following restrictor removal ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit; System overview - Refrigerant circuit (vehicle-specific Workshop Manual).
13 - Condenser
14 - Connection (high-pressure side) at refrigerant circuit
❑ Different versions depending on vehicle ⇒ page 141
15 - Adapter for connection (high-pressure side) to refrigerant circuit
❑ Different versions depending on vehicle ⇒ page 141
❑ From adapter set for refrigerant circuits - VAS 6338/1-
16 - Filler hose to flushing kit for refrigerant circuits
❑ From the high-pressure side connection of the air conditioner compressor at the refrigerant circuit (small‐
er diameter) to the inlet of the refrigerant circuit flushing attachment.
17 - Flushing kit for refrigerant circuits
❑ Different versions and different designs of the refrigerant circuit flushing kit ⇒ Electronic parts catalogue
(Tools; Workshop equipment/tools; Air conditioning/heating).
❑ 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).
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.

5. Refrigerant circuit 131

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

1 - Air conditioner service sta‐

tion
❑ With electronics and a
flushing program, Air
conditioner service sta‐
tion 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 without a flushing
program, the process
must be carried out
manually (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‐
ditioner service station
❑ From the high-pressure
end of the air condition‐
er service station (gen‐
erally red coloured) to
the connection for the
low-pressure end of the
air conditioner compres‐
sor at the refrigerant cir‐
cuit (larger diameter)
3 - Adapter for connection
(low-pressure side) to refriger‐
ant circuit
❑ Different versions de‐
pending on vehicle
⇒ page 141
❑ From adapter set for refrigerant circuits - VAS 6338/1-
4 - Connection (low-pressure side) at refrigerant circuit
❑ Different versions depending on vehicle ⇒ page 141
5 - Adapter for removed expansion valve
❑ Different versions depending on vehicle ⇒ page 141
❑ From adapter set for refrigerant circuits - VAS 6338/1-
6 - Evaporator
7 - Connection to receiver
❑ Different versions depending on vehicle ⇒ page 141
❑ 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; System overview - Re‐
frigerant circuit (vehicle-specific Workshop Manual).
8 - Adapter for bridging removed receiver
❑ Not necessary on all vehicles
❑ Different versions depending on vehicle ⇒ page 141
❑ From adapter set for refrigerant circuits - VAS 6338/1-
9 - Filler hose for refrigerant ⇒ page 141
❑ For example filler hose - VAS 6338/31- (from adapter set for refrigerant circuits - VAS 6338/1- )

132 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 ;
Refrigerant circuit; System overview - Refrigerant circuit (vehicle-specific Workshop Manual).
❑ 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; System overview - 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; System overview - Refriger‐
ant circuit (vehicle-specific Work‐
shop Manual) ⇒ Electronic parts
catalogue .

11 - Connection (high-pressure side) at refrigerant circuit

❑ Different versions depending on vehicle ⇒ page 141
12 - Adapter for connection (high-pressure side) to refrigerant circuit
❑ Different versions depending on vehicle ⇒ page 141
❑ From adapter set for refrigerant circuits - VAS 6338/1-
13 - Filler hose to flushing kit for refrigerant circuits
❑ From the high-pressure side connection of the air conditioner compressor at the refrigerant circuit (small‐
er diameter) to the inlet of the refrigerant circuit flushing attachment.
14 - Flushing kit for refrigerant circuits
❑ Different versions and different designs of the refrigerant circuit flushing kit ⇒ Electronic parts catalogue
(Tools; Workshop equipment/tools; Air conditioning/heating).
❑ 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).
15 - 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
16 - Adapter for sealing outlet to second evaporator
❑ Only required for certain vehicles with “second evaporator” as optional extra
❑ From adapter set for refrigerant circuits - VAS 6338/1-
17 - Adapter for sealing outlet to second evaporator
❑ Only required for certain vehicles with “second evaporator” as optional extra
❑ From adapter set for refrigerant circuits - VAS 6338/1-
18 - Connection (low-pressure side) at refrigerant circuit to second evaporator
❑ Different versions depending on vehicle ⇒ page 141
❑ Only fitted on certain vehicles with “second evaporator” as optional extra
19 - Connection (high-pressure side) at refrigerant circuit to second evaporator
❑ Different versions depending on vehicle ⇒ page 141
❑ Only fitted on certain vehicles with “second evaporator” as optional extra

5. Refrigerant circuit 133

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

20 - Adapter for expansion valve (removed) at second evaporator

❑ Different versions depending on vehicle ⇒ page 141
❑ Only required for certain vehicles with “second evaporator” as optional extra
❑ From adapter set for refrigerant circuits - VAS 6338/1-
21 - Second evaporator
❑ Only fitted on certain vehicles with “second evaporator” as optional extra

5.5.2 Flushing electrically driven air condition‐

er compressor (removing refrigerant oil)
Vehicles with high-voltage system (hybrid vehicles)
For all work on vehicles with a high-voltage system, note the ad‐
ditional warning instructions for working on such vehicles
⇒ “1 Warning instructions when working on vehicles with high-
voltage system”, page 1 and ⇒ Electrical system; Rep. gr. 93 ;
General warning instructions for work on the high-voltage sys‐
tem .

WARNING

Safety hazard: the engine can start unexpectedly.

Before carrying out general work on a vehicle with high-voltage
electrical system, switch off the ignition and remove the ignition
key from the vehicle.

WARNING

Working on vehicles with high-voltage wiring:

134 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

DANGER!

Risk of fatal injury if high-voltage components are damaged.

If work is necessary in the vicinity of high-voltage system com‐

5. Refrigerant circuit 135

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

DANGER!

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock.
♦ The high-voltage system may only be de-energised by a
suitably qualified person (Audi high-voltage technician).
♦ It must be definitely confirmed that the high-voltage sys‐
tem is de-energised. The system may only be de-ener‐
gised using the vehicle diagnostic tester via “Guided Fault
Finding”.
♦ The qualified person (Audi high-voltage technician) en‐
sures that the system is de-energised and secured with
the locking cap - T40262- to prevent anyone from switch‐
ing it on. Furthermore, the qualified person must also store
the ignition key and maintenance connector for high-volt‐
age system - TW - in a safe place as an additional meas‐
ure to prevent the system from being switched back on.
♦ The qualified person (Audi high-voltage technician) marks
the vehicle by attaching the appropriate warning signs.

Note

♦ De-energising high-voltage system:

Re-energising high-voltage system

136 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

DANGER!

High voltage can cause fatal injury.

Note

♦ Re-energising high-voltage system:

DANGER!

When working on a vehicle with the ignition switched on or

– 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

5. Refrigerant circuit 137

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

charger 60A - VAS 5904- in battery standby mode ⇒ Electrical

Note

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 the
need for refrigerant circuit cleaning”, page 278 .
♦ 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 flushing, position the air conditioner compressor so that
the 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 335 .
♦ If an electrically driven air conditioner compressor is renewed,
it is not always necessary to flush the refrigerant circuit. The

138 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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
⇒ “9.1.3 Renewing air conditioner compressor without the
need for refrigerant circuit cleaning”, page 278 .
♦ 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 newly installed must be filled up with the same
quantity of new refrigerant oil as was flushed out of the air
conditioner to be replaced. Example: 120 cm3 of refrigerant oil
was flushed out of the removed air conditioner compressor
and the air conditioner compressor to be newly installed con‐
tains 200 cm3 (see rating plate and
⇒ “10.2.2 Refrigerant oil capacities”, page 335 ). 110 cm3 (120
cm3minus 10 cm3) must be poured out of the air conditioner
compressor to be installed so that the refrigerant circuit con‐
tains the correct quantity of refrigerant oil after the new air
conditioner compressor is installed. If the required 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 filled up with the
same quantity of refrigerant oil as was previously flushed out
of the old air conditioner compressor.
Flushing the electrically driven air conditioner compressor

5. Refrigerant circuit 139

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

1 - Air conditioner service sta‐

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 the refrig‐
erant line to the condenser from
the vehicle for example (or use a
refrigerant 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 side inlet to the high-
pressure side outlet)
❑ To flush as much refrigerant oil as possible out of the air conditioner compressor, position the compressor
with the high-pressure side outlet as low down as possible when flushing

140 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

6 - Refrigerant line
❑ For connection of air conditioner compressor to adapter ⇒ Item 7 (page 141)

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 high-pressure side connection at air conditioner compressor

❑ Different versions depending on vehicle ⇒ page 141
❑ Use the adapter from the VW/Audi passenger vehicle adapter set - VAS 6338/1- (here adapter - VAS
6338/40- ).
8 - Filler hose to flushing kit for refrigerant circuits
❑ From the high-pressure side connection of the air conditioner compressor at the refrigerant circuit (small‐
er diameter) to the inlet of the refrigerant circuit flushing attachment.
9 - Flushing kit for refrigerant circuits
❑ Different versions and different designs of the refrigerant circuit flushing kit ⇒ Electronic parts catalogue
(Tools; Workshop equipment/tools; Air conditioning/heating).
❑ 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).
10 - 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

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 charging hose with 5/8 - 18 UNF connections (short
version e.g. charging hose - VAS 6338/31- ) to connect the
two adapters fitted in place of the reservoir or receiver re‐
moved (contained in VW/Audi passenger vehicle adapter set
- 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 ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - Refrigerant circuit (vehicle-specific Work‐
shop Manual).
♦ The logo of the compressor manufacturer “Zexel” attached to
the air conditioner compressor was modified from “Zexel” to

5. Refrigerant circuit 141

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

“Valeo” from year of production 2006 onwards (change in

manufacturer's name).
Block or screw connections
– Screw connection -A-
– Block connection -B-
Block connections with different types of seal

142 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

– Block connection with radial seal -A- (with plastic or metal

guide -B-)
– Block connection with axial seal -C-
Audi A1 and Audi A2
Vehicle Adapters re‐ Adapters required for Other re‐
quired for con‐ reservoir/receiver con‐ quire‐
nections to air nections 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
♦ Adapter - desiccant bag is re‐ 6338/34-
VAS moved from the re‐ or adapter
6338/12- ceiver at the con‐ - VAS
(low-pres‐ denser and the 6338/39-
sure side) opening is sealed (see notes
again for flushing. below) fit‐
♦ High-pres‐ ted (or old
sure side – Version 2 (receiver removed
Adapter - attached to con‐ expansion
VAS 6338/3- denser): No adapt‐ valve dril‐
or Adapter - er required; the re‐ led open
VAS 6338/2- ceiver is left instal‐ for flushing
(depending led (renewed after and re-in‐
on the design flushing). stalled
of the air con‐ ⇒
ditioner com‐ page 123
pressor and
the corre‐
sponding re‐
frigerant line)

Audi A2 – Compressor Reservoir - Restrictor

(8Z_) manufacturer – Screw connection removed,
2001 ► “Denso” at inlet Adapter - pipe con‐
♦ Adapter - VAS 6338/9- nections
VAS re-assem‐
6338/12- – Block connection bled
(low-pres‐ with axial seal at
sure side) outlet Adapter -
VAS 6338/10-
♦ Adapter -
VAS 6338/2-
(high-pres‐
sure side)

5. Refrigerant circuit 143

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

♦ On the Audi A1/S1, the receiver may be attached or integrated

depending on the version of the condenser. The integrated
receiver is fitted with a desiccant cartridge which can be re‐
newed separately. If the receiver is of the attached type (in‐
troduction not yet finalised), it must be renewed after flushing
⇒ Electronic parts catalogue and ⇒ Heating, air conditioning;
Rep. gr. 87 ; Refrigerant circuit; System overview - refrigerant
circuit (vehicle-specific Workshop Manual).
♦ Different versions of the air conditioning unit (different heat
exchanger and seals, different expansion valve, etc.), de‐
pending on the production period and vehicle identification
number on the Audi A1/S1 ⇒ Electronic parts catalogue . Ve‐
hicles with the type codes “8X1” and “8XA” in the vehicle
identification number are fitted with an expansion valve where
the two refrigerant pipes are screwed on at the top; the adapter
- VAS 6338/34- is compatible here. Vehicles with the type co‐
des “8XF” and “8XK” in the vehicle identification number are
fitted with an expansion valve where the two refrigerant pipes
are screwed on at the bottom; the adapter - VAS 6338/39- is
compatible here ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit; removing and installing expansion valve
(vehicle-specific Workshop Manual).

144 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Audi A3, Audi Q3 and Audi TT

Vehicle Adapters re‐ Adapters required for Other re‐
quired for con‐ reservoir/receiver con‐ quire‐
nections to air nections ments
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 ► ♦ Adapter - 6338/2- (2x re‐ 6338/19-
VAS 6338/7- quired) fitted (or
(low-pres‐ drilled-
sure side) open ex‐
pansion
♦ Adapter - valve e.g.
VAS 6338/2- 6N0 820
(high-pres‐ 679 C fit‐
sure side) ted
⇒
page 123 )
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” or – Depending on the (or drilled-
(8U_ / “Zexel / Va‐ version of the con‐ open ex‐
84_) leo” denser, it may be pansion
2012 ► – Compressor necessary to re‐ valve e.g.
manufacturer move the desiccant 1K0 820
for Audi TT: cartridge from the 679) fitted
“Denso”, receiver on the con‐ ⇒
“Sanden” or denser before page 123
“Delphi” flushing and to seal
♦ Adapter - the opening again
VAS (see note).
6338/12-
(low-pres‐
sure side)
♦ Adapter -
VAS 6338/3-
(high-pres‐
sure side)

Audi A3 – Compressor Receiver (different ver‐ Expansion

(8V_/ manufacturer sions) valve re‐
85_) “Denso” or – No adapter re‐ moved and
2013 ► “Sanden” quired; receiver is adapter -
Audi TT ♦ Adapter - not removed (or is VAS
(FV_) VAS integrated in con‐ 6338/38-
2015 ► 6338/12- denser). (or drilled-
(low-pres‐ open ex‐
sure side) – Depending on the pansion
version of the con‐ valve e.g.
♦ Adapter - denser, it may be 5Q0 820
VAS 6338/3- necessary to re‐ 679 X) in‐
(high-pres‐ move the desiccant stalled
sure side) cartridge from the ⇒
♦ receiver on the con‐ page 123
denser before
flushing and to seal
the opening again
(see note).

5. Refrigerant circuit 145

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 features an integrated
receiver for example. The integrated receiver contains a des‐
iccant 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 vehicles
fitted with this condenser ⇒ Electronic parts catalogue and ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - Refrigerant circuit (vehicle-specific Work‐
shop Manual).
♦ On vehicles with condensers with an integrated receiver / des‐
iccant cartridge which cannot be renewed separately or which
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 ;
Refrigerant circuit; System overview - Refrigerant circuit (ve‐
hicle-specific Workshop Manual) and ⇒ Electronic parts cata‐
logue .

146 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Audi A3 e-tron
Vehicle Adapters re‐ Adapters required for Other re‐
quired for con‐ reservoir/receiver con‐ quire‐
nections to air nections ments
conditioner com‐
pressor
Audi A3 – Compressor Receiver (different ver‐ ♦ Expan‐
(8V_/ manufacturer sions) sion
85_) “Denso” or – No adapter re‐ valve re‐
2013 ► “Sanden” quired; receiver is moved
♦ Adapter - not removed (or is and
VAS integrated in con‐ adapter -
6338/12- denser). VAS
(low-pres‐ – Depending on the 6338/38-
sure side) version of the con‐ (or dril‐
denser, it may be led-open
♦ Adapter - necessary to re‐ expan‐
VAS 6338/3- move the desiccant sion
(high-pres‐ cartridge from the valve
sure side) receiver on the con‐ e.g. 5Q0
denser before 820 679
flushing and to seal X) instal‐
the opening again led
(see note). ⇒
♦ Stop valve - VAS page
6338/42- 123
♦ Shut-off
valves -
N541-
and -
N542-
removed
and two
shut-off
valves -
VAS
6338/42-
installed
in their
place
(see
notes
below)
♦ Restric‐
tor in the
refriger‐
ant line
to the
heat ex‐
changer
for high-
voltage
battery
removed
or refrig‐
erant
line dril‐
led open
(see
notes
below)

5. Refrigerant circuit 147

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Vehicle Adapters re‐ Adapters required for Other re‐

quired for con‐ reservoir/receiver con‐ quire‐
nections to air nections ments
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, re‐
⇒ page 139 move
(Flushing the the re‐
electrically driv‐ friger‐
en air condition‐ ant oil
er compressor) 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

148 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

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

sections. In the first purging 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
purged by the evaporator in the conditioning unit. In the sec‐
ond purging 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 purged by the
evaporator in the heat exchanger for high-voltage battery ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - Refrigerant circuit (vehicle-specific Work‐
shop Manual).
♦ The illustration shows a refrigerant line -A- with a permanently
installed restrictor -B- (without strainer). In order to purge the
refrigerant circuit, this refrigerant line must be drilled open to
5.0 mm using a suitable drill bit (plugged restrictor must be
removed) and cleaned before installation in the rinse circuit.
After purging, the drilled open refrigerant line must be renewed
⇒ 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 condenser manufacturer. This condenser features an
integrated receiver for example. The integrated receiver con‐
tains a desiccant cartridge which is currently not always avail‐
able 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 cata‐
logue and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refriger‐
ant circuit; System overview - Refrigerant circuit (vehicle-
specific Workshop Manual).
♦ On vehicles with condensers with an integrated receiver / des‐
iccant cartridge which cannot be renewed separately or which
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 ;
Refrigerant circuit; System overview - Refrigerant circuit (ve‐
hicle-specific Workshop Manual) and ⇒ Electronic parts cata‐
logue .

5. Refrigerant circuit 149

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Audi 80 ,Audi 90, Audi Coupé, Audi Cabriolet and Audi A4

Vehicle Adapters re‐ Adapters required for Other re‐
quired for con‐ reservoir connections quire‐
nections to air ments
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_), ♦ Adapter - – Screw connection bled
Audi VAG 1785/8- at inlet Adapter -
Cabrio‐ (low-pres‐ VAS 6338/9-
let (8G_) sure side)
► 2002 – Screw connection
Audi A4 ♦ Adapter - at outlet Adapter -
(8D_) VAG 1785/7- VAG 1785/8-
1995► (high-pres‐
sure side)

– Compressor ♦ Version “2”

manufacturer
“Denso” (bloc – Screw connection
k connections at inlet Adapter -
with radial VAS 6338/9-
and axial
seal) – Block connection
♦ Adapter - with axial seal at
VAS outlet Adapter -
6338/12- VAS 6338/10-
(low-pres‐
sure side)
♦ Adapter -
VAS 6338/2-
(high-pres‐
sure side)

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‐
♦ Adapter - let and outlet
VAS ♦ Adapter - VAS
6338/12- 6338/10- (2x re‐
(low-pres‐ quired)
sure side)
♦ Adapter -
VAS 6338/2-
(high-pres‐
sure side)

150 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Vehicle Adapters re‐ Adapters required for Other re‐

quired for con‐ reservoir connections quire‐
nections to air ments
conditioner com‐
pressor
– Compressor ♦ Version “2”
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‐
tioning; Rep. quired)
gr. 87 ; Re‐
frigerant cir‐
cuit; System
overview -
Refrigerant
circuit (vehi‐
cle-specific
Workshop
Manual)
♦ Adapter -
VAS
6338/12-
(low-pres‐
sure side)
♦ Adapter -
VAS 6338/3-
(high-pres‐
sure side)

Audi A4 – Compressor Receiver (different ver‐ Expansion

(8K_) manufacturer sions) valve re‐
2008 ► “Denso” – Adapter not re‐ moved and
♦ Adapter - quired, receiver re‐ Adapter -
VAS mains in position VAS
6338/12- 6338/36-
(low-pres‐ – Depending on the (or drilled-
sure side) version of the con‐ open ex‐
denser, it may be pansion
♦ Adapter - necessary to re‐ valve e.g.
VAS 6338/3- move the desiccant 8K0 820
(high-pres‐ cartridge from the 679 A) fit‐
sure side) receiver on the con‐ ted
denser before ⇒
flushing and to seal page 123
the opening again – Refrig‐
(see note). erant
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.

5. Refrigerant circuit 151

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

♦ The design of the receiver on the Audi A4 (8K_) 2008 > differs
depending on the condenser manufacturer ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - Refrigerant circuit (vehicle-specific Workshop 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. Therefore it may be
necessary to renew the condenser after eliminating any faults
on vehicles fitted with this condenser ⇒ Electronic parts cata‐
logue .
♦ On vehicles with condensers with an integrated receiver / des‐
iccant cartridge which cannot be renewed separately or which
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 ;
Refrigerant circuit; System overview - Refrigerant circuit (ve‐
hicle-specific Workshop Manual) and ⇒ Electronic parts cata‐
logue .

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

Vehicle Adapters re‐ Adapters required for Other re‐
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‐ ♦ Adapter - quired, receiver re‐ Adapter -
back VAS mains in position VAS
(8T_) 6338/12- 6338/36-
2008 ► (low-pres‐ – Depending on the (or drilled-
Audi Q5 sure side) version of the con‐ open ex‐
(8R_ / denser, it may be pansion
83_) ♦ Adapter - necessary to re‐ valve e.g.
2008 ► VAS 6338/3- move the desiccant 8K0 820
Audi A5 (high-pres‐ cartridge from the 679 A) fit‐
Cabrio‐ sure side) receiver on the con‐ ted
let (8F_) denser before ⇒
2009 ► flushing and to seal page 123
the opening again – Refrig‐
(see note). erant
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.

152 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

♦ The design of the receiver varies on these vehicles depending

on the manufacturer of the condenser ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific Workshop Manual). De‐
pending 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. Therefore it may be
necessary to renew the condenser after eliminating any faults
on vehicles fitted with this condenser ⇒ Electronic parts cata‐
logue .
♦ On vehicles with condensers with an integrated receiver / des‐
iccant cartridge which cannot be renewed separately or which
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 ;
Refrigerant circuit; System overview - Refrigerant circuit (ve‐
hicle-specific Workshop Manual) and ⇒ Electronic parts cata‐
logue .

5. Refrigerant circuit 153

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Audi Q5 hybrid
Vehicle Adapters re‐ Adapters required for Other re‐
quired for con‐ receiver connections quire‐
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‐
♦ Adapter - denser, it may be pansion
VAS necessary to re‐ valve e.g.
6338/12- move the desiccant 8K0 820
(low-pres‐ cartridge from the 679 A) fit‐
sure side) receiver on the con‐ ted
denser before ⇒
♦ Adapter - flushing and to seal page 123
VAS 6338/3- the opening again – Refrig‐
(high-pres‐ (see note). erant
sure side) 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.

154 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Vehicle Adapters re‐ Adapters required for Other re‐

quired for con‐ receiver connections quire‐
nections to/on air ments
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- valves -
bat‐ pressure side (to N516-
tery second evaporator removed
cool‐ in battery cooling and a
ing module) shut-off
mod‐ valve -
ule ♦ Adapter - VAS VAS
6338/11- for seal‐ 6338/42-
ing connection on installed
high-pressure side (see
(to second evapo‐ notes
rator in battery cool‐ below)
ing module) or -
♦ Shut-off valve - N516-
VAS 6338/42- or re‐
adapter - VAG moved,
1785/5- to replace drilled
removed refriger‐ open,
ant shut-off valve 1 cleaned
for hybrid battery - and re-
N516- (see notes) installed
(similar
to ex‐
pansion
valve
⇒
pa
ge 123 )
♦ Flushing
the cir‐
cuit in
one or
two
steps
(see
notes)

5. Refrigerant circuit 155

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Vehicle Adapters re‐ Adapters required for Other re‐

quired for con‐ receiver connections quire‐
nections to/on air ments
conditioner com‐
pressor
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 123 ).

156 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Vehicle Adapters re‐ Adapters required for Other re‐

quired for con‐ receiver connections quire‐
nections to/on air ments
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, re‐
⇒ page 139 move
(Flushing the the re‐
electrically driv‐ friger‐
en air condition‐ ant oil
er compressor) 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

5. Refrigerant circuit 157

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 there are two adapters - VAG 1785/5- and
the -N516- should not be drilled open, the circuit can be flush‐
ed with the evaporator in the air conditioning unit in one work
step (re-assemble circuit with one charging hose and two
adapters - VAG 1785/5- ). If there is no adapter - VAS 6338/42-
and only one adapter - VAG 1785/5- , and the -N516- should
not be drilled open, the circuit must be flushed in two opera‐
tions. From the low-pressure connection at the air conditioner
compressor via the evaporator in the air conditioning unit to
the connection for the -N516- removed and from the connec‐
tion for the -N516- removed via the condenser to the high-
pressure connection at the air conditioner compressor.
♦ The design of the receiver varies on these vehicles depending
on the manufacturer of the condenser ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific Workshop Manual). De‐
pending 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. Therefore it may be
necessary to renew the condenser after eliminating any faults
on vehicles fitted with this condenser ⇒ Electronic parts cata‐
logue .
♦ On vehicles with condensers with an integrated receiver / des‐
iccant cartridge which cannot be renewed separately or which
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 ;
Refrigerant circuit; System overview - Refrigerant circuit (ve‐
hicle-specific Workshop Manual) and ⇒ Electronic parts cata‐
logue .

158 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Audi 100, Audi A6 (4A_, 4B_ and 4F_), Audi allroad and Audi V8
Vehicle Adapters re‐ Adapters required for Other re‐
quired for con‐ reservoir connections quire‐
nections to air ments
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 ♦ Adapter - – Screw connection bled
(4B_) VAG 1785/8- at inlet Adapter -
1998 ► (low-pres‐ VAS 6338/9-
Audi all‐ sure side)
road – Screw connection
(4B_) ► ♦ Adapter - at outlet Adapter -
2005 VAG 1785/7- VAG 1785/8-
Audi V8 (high-pres‐
(4C_) ► sure side)
1994
– Compressor ♦ Version “2”
manufacturer
“Denso” (bloc – Screw connection
k connections at inlet Adapter -
with radial VAS 6338/9-
and axial – Block connection
seal) with axial seal at
♦ Adapter - outlet Adapter -
VAS VAS 6338/10-
6338/12- ♦ Version “3”
(low-pres‐ – Block connections
sure side) with axial seal at in‐
♦ Adapter - let and outlet
VAS 6338/2- Adapter - VAS
(high-pres‐ 6338/10- (2x re‐
sure side) 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
♦ Adapter - quired)
VAS
6338/12-
(low-pres‐
sure side)
♦ Adapter -
VAS 6338/3-
(high-pres‐
sure side)

Note

The specifications for the Audi A6 (4F_) 2005 ► also apply to the
Audi S6 and Audi RS 6.

5. Refrigerant circuit 159

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Audi A6 (4G_ or 4X_ for China), Audi A7 (4G_ or 4X_ for China)
Vehicle Adapters re‐ Adapters required for Other re‐
quired for con‐ receiver connections quire‐
nections to air ments
conditioner com‐
pressor
Audi A6 – Compressor Receiver (different ver‐ Expansion
(4G_ / manufacturer sions) valve re‐
4X_) “Denso” – Adapter not re‐ moved and
2011 ► ♦ Adapter - quired, receiver re‐ adapter -
Audi A7 VAS mains in position VAS
(4G_ / 6338/12- 6338/36-
4X_) (low-pres‐ – Depending on the fitted (or
2011 ► sure side) version of the con‐ old expan‐
denser, it may be sion valve
♦ Adapter - necessary to re‐ removed
VAS 6338/3- move the desiccant drilled
(high-pres‐ cartridge from the open for
sure side) receiver on the con‐ flushing
denser before and re-in‐
flushing and to seal stalled
the opening again ⇒
(see note). page 123 ).

Note

♦ On certain versions for China the type designation 4X_ is used

instead of 4G_.
♦ The design of the receiver varies on these vehicles depending
on the manufacturer of the condenser ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific Workshop Manual) and ⇒
Electronic parts catalogue .
♦ On vehicles with condensers with an integrated receiver / des‐
iccant cartridge which cannot be renewed separately or which
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 ;
Refrigerant circuit; System overview - Refrigerant circuit (ve‐
hicle-specific Workshop Manual) and ⇒ Electronic parts cata‐
logue .

160 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Audi A6 hybrid
Vehicle Adapters re‐ Adapters required for Other re‐
quired for con‐ receiver connections quire‐
nections to/on air ments
conditioner com‐
pressor
Audi A6 Adapters re‐ Receiver (different ver‐ Expansion
(4G_) quired for con‐ sions) valve re‐
2012 ► 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 old, dril‐
“Denso” version of the con‐ led-out and
♦ Adapter - denser, it may be cleaned
VAS necessary to re‐ expansion
6338/12- move the desiccant valve
(low-pres‐ cartridge from the ⇒
sure side) receiver on the con‐ page 123 )
denser before installed.
♦ Adapter - flushing and to seal – Refrig‐
VAS 6338/3- the opening again erant
(high-pres‐ (see note). line
sure side) with in‐
ternal
heat
ex‐
chang‐
er is not
re‐
moved
or is re-
instal‐
led af‐
ter in‐
stalla‐
tion of
adapt‐
er.

5. Refrigerant circuit 161

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Vehicle Adapters re‐ Adapters required for Other re‐

162 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Vehicle Adapters re‐ Adapters required for Other re‐

5. Refrigerant circuit 163

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Vehicle Adapters re‐ Adapters required for Other re‐

164 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

♦ On certain versions for China the type designation 4X_ is used

instead of 4G_.
♦ 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 there are two adapters - VAG 1785/5- and
the -N516- should not be drilled open, the circuit can be flush‐
ed with the evaporator in the air conditioning unit in one work
step (re-assemble circuit with one charging hose and two
adapters - VAG 1785/5- ). If there is no adapter - VAS 6338/42-
and only one adapter - VAG 1785/5- , and the -N516- should
not be drilled open, the circuit must be flushed in two opera‐
tions. From the low-pressure connection at the air conditioner
compressor via the evaporator in the air conditioning unit to
the connection for the -N516- removed and from the connec‐
tion for the -N516- removed via the condenser to the high-
pressure connection at the air conditioner compressor.
♦ The design of the receiver varies on these vehicles depending
on the manufacturer of the condenser ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific Workshop Manual). De‐
pending 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. Therefore it may be
necessary to renew the condenser after eliminating any faults
on vehicles fitted with this condenser ⇒ Electronic parts cata‐
logue .
♦ On vehicles with condensers with an integrated receiver / des‐
iccant cartridge which cannot be renewed separately or which
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 ;
Refrigerant circuit; System overview - Refrigerant circuit (ve‐
hicle-specific Workshop Manual) and ⇒ Electronic parts cata‐
logue .

5. Refrigerant circuit 165

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Audi A8
Vehicle Adapters re‐ Adapters required for Other re‐
quired for con‐ reservoir connections quire‐
nections to air ments
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‐
♦ Adapter - – Screw connection bled
VAG 1785/8- at inlet Adapter -
(low-pres‐ VAS 6338/9-
sure side)
– Screw connection
♦ Adapter - at outlet Adapter -
VAG 1785/7- VAG 1785/8-
(high-pres‐
sure side)

– Compressor ♦ Version “2”

manufacturer
“Denso” (bloc – Screw connection
k connections at inlet Adapter -
with radial VAS 6338/9-
and axial – Block connection
seal) with axial seal at
♦ Adapter - outlet Adapter -
VAS VAS 6338/10-
6338/12- ♦ Version “3”
(low-pres‐ – Block connections
sure side) with axial seal at in‐
♦ Adapter - let and outlet
VAS 6338/2- Adapter - VAS
(high-pres‐ 6338/10- (2x re‐
sure side) quired)

Audi A8 – Compressor Reservoir - Restrictor

(4E_) manufacturer – Block connections removed,
2003 ► “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
♦ Adapter - quired)
VAS
6338/12-
(low-pres‐
sure side)
♦ Adapter -
VAS 6338/3-
(high-pres‐
sure side)

166 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Vehicle Adapters re‐ Adapters required for Other re‐

quired for con‐ reservoir connections quire‐
nections to air ments
conditioner com‐
pressor
Audi A8 – Compressor – No adapter re‐ Expansion
(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-
♦ Adapter - opening sealed off fitted (or
VAS again for flushing. old expan‐
6338/12- sion valve
(low-pres‐ removed
sure side) drilled
open for
♦ Adapter - flushing
VAS 6338/3- and re-in‐
(high-pres‐ stalled
sure side) ⇒
page 123 ).
♦ Addi‐ For flushing circuit with
tio‐ evaporator in front air
nally conditioning unit
for a ♦ Adapter - VAS
vehi‐ 6338/5- for sealing
cle 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‐ • An additional bore
tio‐ may have to be
ner) made in the adapt‐
ers (see below) to
be able to seal the
refrigerant lines
with the adapters -
VAS 6338/5- and -
VAS 6338/11-

5. Refrigerant circuit 167

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Vehicle Adapters re‐ Adapters required for Other re‐

quired for con‐ reservoir connections quire‐
nections to air ments
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 123 ).
worked (see below)
to be able to con‐
nect the refrigerant
line to the adapter -
VAS 6338/3-

Note

♦ On vehicles with two evaporators, the refrigerant circuit is

flushed in two operations.
♦ At present the front and rear expansion valves have identical
connections (only the control characteristic differs).

Making additional bore in adapters - VAS 6338/5- and -VAS

6338/11- .

– Make a bore -A- in addition to the bore provided (the dimen‐

sions in the illustration are given in mm).
Rework the adapter - VAS 6338/3- .

168 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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

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

5. Refrigerant circuit 169

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Audi A8 hybrid
Vehicle Adapters re‐ Adapters required for Other re‐
quired for con‐ receiver connections quire‐
nections to/on air ments
conditioner com‐
pressor
Audi A8 Adapters re‐ Receiver (different ver‐ Expansion
(4H_) quired for con‐ sions) valve re‐
2012 ► nections to air – Adapter not re‐ moved and
conditioner com‐ quired, receiver re‐ adapter -
pressor mains in position VAS
– Compressor 6338/18-
manufacturer – Depending on the (or old, dril‐
“Denso” version of the con‐ led-out and
♦ Adapter - denser, it may be cleaned
VAS necessary to re‐ expansion
6338/12- move the desiccant valve
(low-pres‐ cartridge from the ⇒
sure side) receiver on the con‐ page 123 )
denser before installed.
♦ Adapter - flushing and to seal – Refrig‐
VAS 6338/3- the opening again erant
(high-pres‐ (see note). line
sure side) with in‐
ternal
heat
ex‐
chang‐
er is not
re‐
moved
or is re-
instal‐
led af‐
ter in‐
stalla‐
tion of
adapt‐
er.

170 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Vehicle Adapters re‐ Adapters required for Other re‐

5. Refrigerant circuit 171

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Vehicle Adapters re‐ Adapters required for Other re‐

172 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Vehicle Adapters re‐ Adapters required for Other re‐

5. Refrigerant circuit 173

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

♦ On vehicles with two evaporators, the refrigerant circuit is

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 one shut-off valve - VAS
6338/42- , install on the -N516- and open, if there is no shut-
off valve - VAS 6338/42- , but two adapters - VAG 1785/5- and
the -N516- should not be drilled open, the circuit can be flush‐
ed with the evaporator in the air conditioning unit in one work
step (re-assemble circuit with one charging hose and two
adapters - VAG 1785/5- ). If there is no adapter - VAS 6338/42-
and only one adapter - VAG 1785/5- , and the -N516- should
not be drilled open, the circuit must be flushed in two opera‐
tions. From the low-pressure connection at the air conditioner
compressor via the evaporator in the air conditioning unit to
the connection for the -N516- removed and from the connec‐
tion for the -N516- removed via the condenser to the high-
pressure connection at the air conditioner compressor.
♦ The design of the receiver varies on these vehicles depending
on the manufacturer of the condenser ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific Workshop Manual). De‐
pending 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. Therefore it may be
necessary to renew the condenser after eliminating any faults
on vehicles fitted with this condenser ⇒ Electronic parts cata‐
logue .
♦ On vehicles with condensers with an integrated receiver / des‐
iccant cartridge which cannot be renewed separately or which
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 ;
Refrigerant circuit; System overview - Refrigerant circuit (ve‐
hicle-specific Workshop Manual) and ⇒ Electronic parts cata‐
logue .

174 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Audi Q7
Vehicle Adapters re‐ Adapters required for Other re‐
quired for con‐ connections to receiv‐ quire‐
nections to air er / to second evapo‐ ments
conditioner com‐ rator
pressor
Audi Q7 – Compressor – No adapter re‐ Expansion
(4L_) manufacturer quired, the dryer is valve re‐
2006 ► “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 sealed off 6338/17-
one ♦ Adapter - again. or adapter
evap‐ VAS - VAS
ora‐ 6338/12- 6338/33-
tor (2 (low-pres‐ fitted de‐
zone sure side) pending on
air version of
con‐ ♦ Adapter - expansion
di‐ VAS 6338/3- valve (or
tio‐ (high-pres‐ drilled-
ner) sure side) open ex‐
pansion
valve e.g.
7L0 820
712 A, 7H0
820 679 B
or 7L0 820
679 C fit‐
ted
⇒
page 123 )
⇒ 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)

5. Refrigerant circuit 175

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Vehicle Adapters re‐ Adapters required for Other re‐

quired for con‐ connections to receiv‐ quire‐
nections to air er / to second evapo‐ ments
conditioner com‐ rator
pressor
For flushing second Expansion
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 123 )
on high-pressure ⇒ Elec‐
side (to second tronic parts
evaporator). catalogue

Note

On vehicles with two evaporators, the refrigerant circuit is flushed

in two operations.

Audi R8
Vehicle Adapters re‐ Adapters required for Other re‐
quired for con‐ reservoir connections quire‐
nections to air ments
conditioner com‐
pressor
Audi R8 – Compressor Reservoir - Restrictor
(42_) manufacturer – Block connections removed,
2008 ► “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
♦ Adapter - quired)
VAS
6338/12-
(low-pres‐
sure side)
♦ Adapter -
VAS 6338/3-
(high-pres‐
sure side)

176 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 without removing
the air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 ; Refrigerant circuit; System overview - Refrigerant
circuit (vehicle-specific Workshop Manual). However the
quantity of refrigerant oil cannot be determined while the air
conditioner compressor is installed, which means that flushing
the refrigerant circuit does not make any sense with an instal‐
led air conditioner compressor.
♦ The two condensers are flushed in situ in the direction oppo‐
site to that of the refrigerant flow.

5.6 Tracing leaks in refrigerant circuit

Vehicles with high-voltage system (hybrid vehicles)
For all work on vehicles with a high-voltage system, note the ad‐
ditional warning instructions for working on such vehicles
⇒ “1 Warning instructions when working on vehicles with high-
voltage system”, page 1 and ⇒ Electrical system; Rep. gr. 93 ;
General warning instructions for work on the high-voltage sys‐
tem .

WARNING

Safety hazard: the engine can start unexpectedly.

Before carrying out general work on a vehicle with high-voltage
electrical system, switch off the ignition and remove the ignition
key from the vehicle.

WARNING

Working on vehicles with high-voltage wiring:

5. Refrigerant circuit 177

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

DANGER!

Risk of fatal injury if high-voltage components are damaged.

If work is necessary in the vicinity of high-voltage system com‐

Note

The leak detection work at the refrigerant circuit using an elec‐

tronic leak detector or a UV leak detector lamp can usually also
be performed on the components of the high-voltage system with‐
out having to de-energise the high-voltage system.

De-energising high-voltage system

178 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

DANGER!

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock.
♦ The high-voltage system may only be de-energised by a
suitably qualified person (Audi high-voltage technician).
♦ It must be definitely confirmed that the high-voltage sys‐
tem is de-energised. The system may only be de-ener‐
gised using the vehicle diagnostic tester via “Guided Fault
Finding”.
♦ The qualified person (Audi high-voltage technician) en‐
sures that the system is de-energised and secured with
the locking cap - T40262- to prevent anyone from switch‐
ing it on. Furthermore, the qualified person must also store
the ignition key and maintenance connector for high-volt‐
age system - TW - in a safe place as an additional meas‐
ure to prevent the system from being switched back on.
♦ The qualified person (Audi high-voltage technician) marks
the vehicle by attaching the appropriate warning signs.

Note

♦ De-energising high-voltage system:

Re-energising high-voltage system

5. Refrigerant circuit 179

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

DANGER!

High voltage can cause fatal injury.

Note

♦ Re-energising high-voltage system:

DANGER!

When working on a vehicle with the ignition switched on or

– 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

180 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

charger 60A - VAS 5904- in battery standby mode ⇒ Electrical

Note

Vehicles with start/stop system

WARNING

Injury risk due to automatic engine start (vehicles with start/

All vehicles

WARNING

Risk of injury (frostbite).

Refrigerant may emerge if the refrigerant circuit has not been
drained.

5. Refrigerant circuit 181

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

♦ Minor leaks can be detected with an electronic leak detector

or UV leak detector lamp for example.
♦ 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.
♦ There are numerous systems available on the market for the
detection of refrigerant circuit leaks. Not all of these yield un‐
equivocal results and, if not employed in the specified manner,
may indicate leaks at various refrigerant circuit components
although these are actually intact. In addition, certain proce‐
dures can lead to damage to components of refrigerant cir‐
cuits.

♦ Renew components found to be leaking (do not repair).

♦ 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 101 .

Caution

♦ Audi does not permit the use of chemical substances

(sealing additives) to seal leaks in the refrigerant circuit.
♦ 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). The
refrigerant circuit can therefore only be repaired by renewing all
the components which have come into contact with this sub‐
stance.

182 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

⇒ “5.6.1 Tracing leaks in refrigerant circuit using electronic leak

detector (e.g. V.A.G 1796)”, page 183
⇒ “5.6.2 Tracing leaks in refrigerant circuit with leak detection
system VAS 6201”, page 184
⇒ “5.6.3 Establishing leaks by way of vacuum test with air condi‐
tioner service station or nitrogen pressure test”, page 194

5.6.1 Tracing leaks in refrigerant circuit using

electronic leak detector (e.g. V.A.G
1796)
Vehicles with high-voltage system (hybrid vehicles)
For all work on vehicles with a high-voltage system, note the ad‐
ditional warning instructions for working on such vehicles
⇒ “1 Warning instructions when working on vehicles with high-
voltage system”, page 1 and ⇒ Electrical system; Rep. gr. 93 ;
General warning instructions for work on the high-voltage sys‐
tem .
All vehicles

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 101 .

Note

♦ If evacuation already reveals a major leak, locate it and elim‐

inate it as described ⇒ page 101 .
♦ 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.

5. Refrigerant circuit 183

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

– Pour roughly 100 g of refrigerant into the evacuated refrigerant

circuit and perform leak detection as for a refrigerant circuit
charged with refrigerant ⇒ page 184 .
Leak detection procedure for refrigerant circuit charged with re‐
frigerant:
– Switch off ignition.
– Start up the leak detector in line with the operating instructions.
– Always hold the probe tip under the location of the suspected
leak.
If the clicking rate increases or a warning tone sounds (depends
on model), this indicates that the leak has been located (refer to
operating instructions for leak detector).

Note

♦ Refrigerant gas is quickly dispersed by the 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
Vehicles with high-voltage system (hybrid vehicles)
For all work on vehicles with a high-voltage system, note the ad‐
ditional warning instructions for working on such vehicles
⇒ “1 Warning instructions when working on vehicles with high-
voltage system”, page 1 and ⇒ Electrical system; Rep. gr. 93 ;
General warning instructions for work on the high-voltage sys‐
tem .

184 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

All vehicles

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
becomes distributed with the refrigerant oil when the air con‐
ditioner is switched on.
♦ The air conditioner must be operated for at least 60 min. to
distribute the additive throughout the refrigerant circuit (the air
conditioner compressor must run). Depending on the extent of
the leak, the leakage location may already become visible un‐
der 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 side.
♦ If the UV leak detection additive is applied via the service con‐
nection on the low-pressure side with the refrigerant circuit
charged, a small quantity of UV leak detection additive re‐
mains in the service connection. Remove carefully so as to
avoid subsequent erroneous leak detection.
♦ If a component forming part of a circuit into which the UV leak
detection additive is poured has to be renewed, thoroughly
clean the joints with the other components after assembling
the refrigerant circuit. Otherwise, the residual UV leak detec‐
tion additive at the joint could be erroneously identified as a
leakage 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. The refrigerant oil drained off is not to be poured
back in. Replace 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 a certain amount of refrigerant oil has been
renewed, just add the corresponding quantity of leak detection
fluid. After renewing 100 ml of refrigerant oil on a vehicle con‐
taining 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

5. Refrigerant circuit 185

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 101 .

Note

♦ If evacuation already reveals a major leak, locate and elimi‐

nate it as described ⇒ page 194 and ⇒ page 101 .
♦ 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 187 .

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 186 .
♦ Adding UV leak detection additive to the refrigerant circuit us‐
ing the leak detection system - VAS 6201- ⇒ page 187 .
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 294 .

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 332 .

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
(Tools; Workshop equipment/tools; Air conditioning/heating).

186 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

♦ 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

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

distribute the additive throughout the refrigerant circuit (the air
conditioner compressor must run). Depending on the extent of
the leak, the leakage location may already become visible un‐
der UV light within this period.
♦ Depending on its magnitude and location, it may now take
several days for sufficient refrigerant oil with UV leak detection
additive to emerge to clearly localise the leakage point.

– Use a UV lamp VAS 6196/4 to locate the refrigerant circuit leak

⇒ page 193 .
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-

5. Refrigerant circuit 187

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 332 .
♦ 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).

188 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

– Assemble the hand pump - VAS 6201- , item -1- with the car‐
tridge, item -2- -VAS 6201/2- .
– Insert filler tube - VAS 6201/8- ( ⇒ page 188 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 191 .
♦ Addition of UV leak detection additive to the refrigerant circuit
by way of an open connection ⇒ page 190 .

5. Refrigerant circuit 189

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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

poured into a refrigerant circuit in the course of previous repair
work: Only add new UV leak detection fluid if refrigerant oil is re‐
newed. If only a certain amount of refrigerant oil has been re‐
newed, just add the corresponding quantity of UV leak detection
additive. After renewing 100 ml of refrigerant oil on a vehicle con‐
taining 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.
– Evacuate and charge the refrigerant circuit as specified
⇒ page 101 and ⇒ page 105 .
– Start up the air conditioner.

Note

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

distribute the additive throughout the refrigerant circuit (the air
conditioner compressor must run). Depending on the extent of
the leak, the leakage location may already become visible un‐
der UV light within this period.
♦ 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.

– Use a UV lamp VAS 6196/4 to locate the refrigerant circuit leak

⇒ page 193 .

190 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Adding UV leak detection additive with refrigerant circuit charged

Note

♦ 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 a certain amount of refrigerant oil has been
renewed, just add the corresponding quantity of leak detection
fluid. After renewing 100 ml of refrigerant oil on a vehicle con‐
taining 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. Remove carefully so as to avoid subse‐
quent erroneous leak detection.

The cartridge -A- contains 15.4 ml of UV leak detection additive

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

– Switch off ignition.

– Detach cap from service connection on low-pressure side of
refrigerant circuit.
– Assemble the hand pump - VAS 6201- , item -1- with the car‐
tridge, item -2- -VAS 6201/2- .
– Insert the tube - VAS 6201/8- ( ⇒ page 188 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.

5. Refrigerant circuit 191

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

– Cover the area around the service connection on the vehicle

with sheeting or absorbent paper.
– Connect the filler unit to the refrigerant circuit service connec‐
tion on the vehicle.
– Open the service connection by screwing in the 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).

192 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

– Detach the filler unit from the service connection.

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

Note

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

distribute the additive throughout the refrigerant circuit (the air
conditioner compressor must run). Depending on the extent of
the leak, the leakage location may already become visible un‐
der UV light within this period.
♦ 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.

– Use a UV lamp VAS 6196/4 to locate the refrigerant circuit leak

⇒ page 193 .
Locating refrigerant circuit leaks with UV lamp VAS 6196/4

WARNING

Never look into the UV lamp.

Never point the UV lamp at other people.

5. Refrigerant circuit 193

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

♦ After adding the UV leak detection additive, the air conditioner

must be operated for at least 60 min. to distribute the additive
throughout the refrigerant circuit (the air conditioner compres‐
sor must run). 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 condensate and emerge via the conden‐
sate drain. As considerable work is required on most vehicles
to gain access to the evaporator, a check at the condensate
drain for example can provide an indication of evaporator leak‐
age. This does however require 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. In such areas it
may therefore be appropriate to use an electronic leak detec‐
tor for leak localisation
⇒ “5.6.1 Tracing leaks in refrigerant circuit using electronic
leak detector (e.g. V.A.G 1796)”, page 183 .

– Move the 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 the UV lamp and illuminate the components of the
refrigerant circuit. Locations at which leakage has resulted in
the emergence of refrigerant, refrigerant oil and thus also UV
leak detection additive show up under UV light (fluorescent).

5.6.3 Establishing leaks by way of vacuum

test with air conditioner service station
or nitrogen pressure test
Vehicles with high-voltage system (hybrid vehicles)
For all work on vehicles with a high-voltage system, note the ad‐
ditional warning instructions for working on such vehicles
⇒ “1 Warning instructions when working on vehicles with high-
voltage system”, page 1 and ⇒ Electrical system; Rep. gr. 93 ;

194 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

General warning instructions for work on the high-voltage sys‐

tem .
All vehicles
– Switch off ignition.
♦ 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 101

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 amount of air ingressing or nitrogen escaping may
not be sufficient to produce a noise permitting detection of the
fault location.
♦ 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 101 .

5. Refrigerant circuit 195

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

6 Problems with refrigerant circuit

⇒ “6.1 Possible complaints about refrigerant circuit”, page 196

6.1 Possible complaints about refrigerant

circuit
⇒ “6.1.1 Test requirements”, page 196
⇒ “6.1.2 Possible complaints”, page 196

6.1.1 Test requirements

• Electrical system, vacuum system and air duct fault finding has
not revealed any faults ⇒ Vehicle diagnostic tester (“self-di‐
agnosis” or “Guided Fault Finding” function for air conditioner),
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations and ⇒ Heating, air conditioning or ⇒ Air conditioning .
• 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 problems marked *, refer to ⇒ page 206 “Checking

pressures”.
♦ If problems are only encountered at one evaporator on vehi‐
cles fitted with two evaporators, also check the pressures in
the refrigerant circuit.
♦ Observe test requirements ⇒ page 196 .

♦ Total cooling system failure.*

♦ Insufficient cooling output at all vehicle or 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). *
♦ No or insufficient cooling at one or via both evaporators (on
vehicles with high-voltage system and battery cooling). *
♦ Air conditioner compressor, air conditioning system magnetic
clutch - N25- or air conditioner compressor regulating valve -
N280- shut off by a pressure switch (e.g. -F73-, -F118-, -F129-
-F129- or by the operating and display unit for Climatronic air
conditioning system - E87- or the Climatronic control unit -
J255- ) on account of excessive or inadequate pressure. *
♦ No or sharp decrease in fresh-air supply after driving several
miles (evaporator iced up). *
In addition, the following problems may occur:
Air conditioner compressor noise
– Re-tighten the bolts for the air conditioner compressor and the
compressor holder using a torque wrench.

196 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

– Check the routing of the refrigerant lines; they must not touch
other components and must not be subject to strain (align if
necessary).
Noise (refrigerant hammer) occurring immediately after switching
on the air conditioner and/or when cornering or braking
– Discharge, evacuate and re-charge the 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, on
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 the 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 not be damaged
and must be properly installed (to stop water running into the
evaporator).
– Check the plenum chamber water drains; they must not be
blocked (e.g. by leaves).

6. Problems with refrigerant circuit 197

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

7 Connecting air conditioner service

station
Vehicles with high-voltage system (hybrid vehicles)
For all work on vehicles with a high-voltage system, note the ad‐
ditional warning instructions for working on such vehicles
⇒ “1 Warning instructions when working on vehicles with high-
voltage system”, page 1 and ⇒ Electrical system; Rep. gr. 93 ;
General warning instructions for work on the high-voltage sys‐
tem .

WARNING

Safety hazard: the engine can start unexpectedly.

Before carrying out general work on a vehicle with high-voltage
electrical system, switch off the ignition and remove the ignition
key from the vehicle.

WARNING

Working on vehicles with high-voltage wiring:

198 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

DANGER!

Risk of fatal injury if high-voltage components are damaged.

If work is necessary in the vicinity of high-voltage system com‐

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.

De-energising high-voltage system

7. Connecting air conditioner service station 199

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Air conditioner with refrigerant R134a - Edition 11.2014

DANGER!

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock.
♦ The high-voltage system may only be de-energised by a
suitably qualified person (Audi high-voltage technician).
♦ It must be definitely confirmed that the high-voltage sys‐
tem is de-energised. The system may only be de-ener‐
gised using the vehicle diagnostic tester via “Guided Fault
Finding”.
♦ The qualified person (Audi high-voltage technician) en‐
sures that the system is de-energised and secured with
the locking cap - T40262- to prevent anyone from switch‐
ing it on. Furthermore, the qualified person must also store
the ignition key and maintenance connector for high-volt‐
age system - TW - in a safe place as an additional meas‐
ure to prevent the system from being switched back on.
♦ The qualified person (Audi high-voltage technician) marks
the vehicle by attaching the appropriate warning signs.

Note

♦ De-energising high-voltage system:

Re-energising high-voltage system

200 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

DANGER!

High voltage can cause fatal injury.

Note

♦ Re-energising high-voltage system:

DANGER!

When working on a vehicle with the ignition switched on or

– 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

7. Connecting air conditioner service station 201

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

charger 60A - VAS 5904- in battery standby mode ⇒ Electrical

Note

Vehicles with start/stop system

WARNING

Injury risk due to automatic engine start (vehicles with start/

All vehicles
– Switch off ignition.
⇒ “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 202
⇒ “7.2 Connecting air conditioner service station - vehicles with
no connection on the low-pressure side of the refrigerant circuit”,
page 203

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
– Switch off ignition.
– Connect air conditioner service station to power supply.

202 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

– Connect quick-release coupling adapters to the charging ho‐

ses of the air conditioner service station (handwheels not
screwed in/hand shut-off valve not open).
– Switch on the air conditioner service station and evacuate the
charging hoses (only necessary if there is air in the charging
hoses).
– Switch off 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).
– 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 with no or an inaccessible connection at the air con‐

ditioner compressor, remove the low-pressure switch for air con‐
ditioning system - F73- (jumper the contacts in the connector for
the low-pressure switch for air conditioning system - F73- ) and
screw an adapter to this connection ⇒ Heating, air conditioning;
Rep. gr. 87 ; Refrigerant circuit; System overview - Refrigerant
circuit (vehicle-specific Workshop Manual).

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. Connecting air conditioner service station 203

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Air conditioner with refrigerant R134a - Edition 11.2014

⇒ “7.2.1 Connecting air conditioner service station to refrigerant

circuit with adapter set for refrigerant circuit V.A.G 1786 ”,
page 204
⇒ “7.2.2 Connecting air conditioner service station to refrigerant
circuit with adapter V.A.G 1785/10”, page 204
⇒ “7.2.3 Connecting air conditioner service station for measuring
and testing”, page 205

7.2.1 Connecting air conditioner service sta‐

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).

7.2.2 Connecting air conditioner service sta‐

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- .

204 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

To minimise the amount of air and moisture ingressing into the

charging hoses and thus into the refrigerant circuit, the charging
hoses should be connected together 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)
– Perform planned tests and measurements.

7.2.3 Connecting air conditioner service sta‐

tion for measuring and testing
– Switch off ignition.
– Connect air conditioner service station to power supply.
– Assemble adapter set and screw onto connection on low-
pressure side.
– Connect quick-release coupling adapters to the charging ho‐
ses of the air conditioner service station (handwheels not
screwed in/hand shut-off valve not open).
– Switch on the air conditioner service station and evacuate the
charging hoses (only necessary if there is air in the charging
hoses).
– 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).
– Perform planned tests and measurements.

7. Connecting air conditioner service station 205

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
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8 Checking pressures
Vehicles with high-voltage system (hybrid vehicles)
For all work on vehicles with a high-voltage system, note the ad‐
ditional warning instructions for working on such vehicles
⇒ “1 Warning instructions when working on vehicles with high-
voltage system”, page 1 and ⇒ Electrical system; Rep. gr. 93 ;
General warning instructions for work on the high-voltage sys‐
tem .

WARNING

Safety hazard: the engine can start unexpectedly.

Before carrying out general work on a vehicle with high-voltage
electrical system, switch off the ignition and remove the ignition
key from the vehicle.

WARNING

Working on vehicles with high-voltage wiring:

206 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

DANGER!

Risk of fatal injury if high-voltage components are damaged.

If work is necessary in the vicinity of high-voltage system com‐

Note

When working on the refrigerant circuit using the air conditioner

service station (here: checking pressure), the high-voltage sys‐
tem does not usually have to be de-energised.

De-energising high-voltage system

8. Checking pressures 207

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

DANGER!

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock.
♦ The high-voltage system may only be de-energised by a
suitably qualified person (Audi high-voltage technician).
♦ It must be definitely confirmed that the high-voltage sys‐
tem is de-energised. The system may only be de-ener‐
gised using the vehicle diagnostic tester via “Guided Fault
Finding”.
♦ The qualified person (Audi high-voltage technician) en‐
sures that the system is de-energised and secured with
the locking cap - T40262- to prevent anyone from switch‐
ing it on. Furthermore, the qualified person must also store
the ignition key and maintenance connector for high-volt‐
age system - TW - in a safe place as an additional meas‐
ure to prevent the system from being switched back on.
♦ The qualified person (Audi high-voltage technician) marks
the vehicle by attaching the appropriate warning signs.

Note

♦ De-energising high-voltage system:

Re-energising high-voltage system

208 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

DANGER!

High voltage can cause fatal injury.

Note

♦ Re-energising high-voltage system:

DANGER!

When working on a vehicle with the ignition switched on or

– 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

8. Checking pressures 209

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

charger 60A - VAS 5904- in battery standby mode ⇒ Electrical

Note

Vehicles with start/stop system

WARNING

Injury risk due to automatic engine start (vehicles with start/

210 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

All vehicles
⇒ “8.1 Checking pressures in refrigerant circuit with air conditioner
service station (with ignition switched off)”, page 211
⇒ “8.2 Checking pressures on vehicles with a restrictor and res‐
ervoir (with internally regulated air conditioner compressor) ”,
page 216
⇒ “8.3 Checking pressures on vehicles with an expansion valve
and receiver (with internally regulated air conditioner compressor)
”, page 220
⇒ “8.4 Checking pressures on vehicles with restrictor, reservoir
and air conditioner compressor regulating valve N280 (with ex‐
ternally regulated air conditioner compressor)”, page 226
⇒ “8.5 Checking pressures on vehicles with expansion valve, re‐
ceiver and air conditioner compressor regulating valve N280 (with
externally regulated air conditioner compressor)”, page 234
⇒ “8.6 Checking pressures on vehicles with an electrically driven
air conditioner compressor (vehicles with a high-voltage system)
”, page 246

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‐
erant circuit; System overview - Refrigerant circuit (vehicle-
specific Workshop Manual)
♦ Depending on the version of the air conditioner compressor,
the high-pressure side of the air conditioner compressor may
be fitted with a valve to prevent the backflow of liquid refriger‐
ant into the compressor after switching off the air conditioning
system. If an air conditioner compressor with this valve is fitted
on a vehicle with a refrigerant circuit with an expansion valve,
a relatively long period may elapse before the pressure on the
high-pressure side decreases (the expansion valve is cold and
the pressure on the low-pressure side increases rapidly after
switch-off, the expansion valve closes 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.

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 conditioner fails repeatedly or sporadically (no cooling/
heating output) after long journeys; after the ignition is switch‐
ed off and waiting a short while, the air conditioner functions
properly again.
♦ Misting up of the windows (front windscreen, side windows
and / or rear windscreen) on the inside after a long journey;

8. Checking pressures 211

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 sender measured value
is too low under the usage conditions outlined by the customer
(at ambient temperature above 0 °C, colder than 0 °C for a
lengthy period although -N280- is currently not being actuated)
or too high (greater than approx. 10 °C although the air con‐
ditioner is functioning properly), the evaporator may ice up due
to the incorrect measured value ⇒ Vehicle diagnostic tester
(“self-diagnosis” or “Guided Fault Finding” function for air con‐
ditioner) and ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐
frigerant circuit; System overview - Refrigerant circuit (vehicle-
specific Workshop Manual).
– On vehicles without a 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's and passenger's side, 4 or 5 bars for fresh-air
blower speed, air outlet to footwell and fresh-air mode. If the
measured value of the sender is too low (at ambient temper‐
ature above 0 °C, colder than 0 °C for lengthy period).
– Check refrigerant pipe between evaporator and reservoir
(thick pipe, low-pressure side) with engine running. If this pipe
is severely iced up when the problem occurs (a thin ice layer
is permissible), this is a further indication that the temperature
in the evaporator 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 212
⇒ “8.1.2 Checking pressures ”, page 214
⇒ “8.1.3 Continuation of testing depending on design of refriger‐
ant circuit ”, page 216

8.1.1 Test requirements

• Radiator and condenser clean (clean if necessary)
• Thermal insulation at expansion valve OK and properly instal‐
led.*
• The ribbed belt is OK and properly tensioned. / belts for air
conditioner compressor and alternator OK and properly ten‐
sioned.*
• All air ducts, covers and seals OK and properly installed.
• Electrical system and vacuum system fault-finding has not re‐
vealed any faults*. ⇒ Vehicle diagnostic tester (“self-diagno‐
sis” or “Guided Fault Finding” function for air conditioner) and
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - Refrigerant circuit (vehicle-specific Work‐
shop Manual).
• Air conditioner self-diagnosis has not revealed any faults (with
engine running and air conditioner switched on), no compres‐
sor shut-off criteria displayed in measured value block (vehi‐
cles with “air conditioner” self-diagnosis only) * ⇒ Vehicle
diagnostic tester (“self-diagnosis” or “Guided Fault Finding”
function for air conditioner) and ⇒ Heating, air conditioning;

212 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Rep. gr. 87 ; Refrigerant circuit; System overview - Refrigerant

circuit (vehicle-specific Workshop Manual).
• 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-
specific Workshop Manual).
• Engine at operating temperature
• Vehicle not exposed to sunlight ⇒ Heating, air conditioning;
Rep. gr. 00 ; Repair instructions; Checking the cooling output
(vehicle-specific Workshop Manual).
• Ambient temperature above 15 ° C
• All dash panel vents open.
– Start engine.
Setting at the operating and display unit for Climatronic air con‐
ditioning system - E87- or the Climatronic control unit - J255- (and
the rear Climatronic operating and display unit - E265- on vehicles
with two air conditioner units):
– Preselect “Auto” mode (air conditioner compressor on).
– Set “LO” temperature for driver's and front passenger's 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 air recirculation 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:
• Operation of radiator fan(s) - V7- (at least 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.
• Recirculated/fresh-air flap set to “Recirculated air mode” (with‐
in 1 min. after starting vehicle, air-flow flap is closed and
recirculated-air flap opened)*
• 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).*

8. Checking pressures 213

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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 air conditioner com‐
pressor drive unit is fitted with an overload protection which is
tripped if the air conditioner compressor is not operating smoothly
⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐
pressor (vehicle-specific Workshop Manual).

8.1.2 Checking pressures

♦ Observe test requirements ⇒ page 212 .
– Switch off ignition.
– Connect air conditioner service station ⇒ page 198 .
– 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

♦ Temperature of refrigerant circuit components should be equal

to ambient temperature (the pressure will deviate from the val‐
ues 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 corresponds to
1 bar absolute. On the scales of most pressure gauges, 0 bar
corresponds to an absolute 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- for which the measured pres‐
sure is displayed in the measured value block, the pressure
measured should coincide with the values in the table ⇒ Ve‐
hicle diagnostic tester (“Self-diagnosis” or “Guided Fault Find‐
ing” for air conditioner) and ⇒ Heating, air conditioning; Rep.
gr. 87 ; Refrigerant circuit; System overview - refrigerant cir‐
cuit (vehicle-specific 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.

214 Rep. gr.87 - Air conditioning system

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Air conditioner with refrigerant R134a - Edition 11.2014

The pressure in the refrigerant circuit is lower than indicated in

the table.
Not enough refrigerant in circuit
– Determine refrigerant circuit leaks ⇒ page 177 .
– Check high-pressure safety valve.
If the high-pressure safety valve has blown off:
– Check actuation of the radiator fans.
– Check for constricted refrigerant line and hose cross-sections
caused by inadequate bending radii.
– Check refrigerant pipes and hoses for external damage.
– If no fault is found, clean refrigerant circuit (by flushing with
refrigerant R134a ⇒ page 116 or blowing out with compressed
air and nitrogen ⇒ page 108 ).
The pressure in the refrigerant circuit corresponds to that indica‐
ted in the table or is higher.
– Start engine.
– 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 measured value
block ⇒ Vehicle diagnostic tester (“self-diagnosis” or “Guided
Fault Finding” function for air conditioner) and ⇒ Heating, air
conditioning; Rep. gr. 87 ; Air conditioner compressor (vehicle-
specific Workshop Manual).

If the air conditioner compressor is not driven when the engine is

running or the regulating valve is not actuated:
– Establish and eliminate the cause e.g. by interrogating the air
conditioner event recorder.
– 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 the low-pressure switch has been removed to connect the

air conditioner service station, jumper the electrical connec‐
tions in the relevant connector for pressure measurement.
♦ The air conditioner compressor is driven by the engine via the
air conditioning system magnetic clutch - N25- .
♦ The air conditioner compressor regulating valve - N280- is ac‐
tuated by the operating and display unit for Climatronic air
conditioning system - E87- or the Climatronic control unit -
J255- ⇒ Vehicle diagnostic tester (“self-diagnosis” or “Guided
Fault Finding” function for air conditioner) and ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - Refrigerant circuit (vehicle-specific Workshop Manual).

8. Checking pressures 215

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♦ Continuation of testing depending on design of refrigerant cir‐

cuit ⇒ page 216

8.1.3 Continuation of testing depending on

design of refrigerant circuit
♦ Checking pressures on vehicles with a restrictor and reservoir
(with internally regulated air conditioner compressor)
⇒ page 216
♦ Checking pressures on vehicles with an expansion valve and
receiver (with internally regulated air conditioner compressor)
⇒ page 220
♦ Checking pressures on vehicles with restrictor, reservoir and
air conditioner compressor regulating valve - N280- (with ex‐
ternally regulated air conditioner compressor) ⇒ page 226
♦ Checking pressures on vehicles with expansion valve, receiv‐
er and air conditioner compressor regulating valve - N280-
(with externally regulated air conditioner compressor)
⇒ page 234

8.2 Checking pressures on vehicles with a

restrictor and reservoir (with internally
regulated air conditioner compressor)

Note

♦ Connect air conditioner service station ⇒ page 198 .

♦ Observe test requirements ⇒ page 206 .

– Check the pressures in the refrigerant circuit (with the air con‐
ditioner service station) with the ignition switched off
⇒ page 211 .
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
conditioner service station.

Note

♦ Switching pressures for refrigerant circuit switches are vehi‐

cle-specific.
♦ The connection with valve for the low-pressure switch or at the
evaporator is only to be used for vehicles with no service con‐
nection on the low-pressure side and an inaccessible connec‐
tion at the air conditioner compressor or reservoir (measure‐
ment accuracy). Only applies for certain vehicles ⇒ Heating,
air conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - Refrigerant circuit (vehicle-specific Workshop Manual).

216 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

⇒ “8.2.1 Specifications for pressures in refrigerant circuit”,

page 217

8.2.1 Specifications for pressures in refriger‐

ant circuit
High-pressure side:
Increasing from initial pressure (on 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 fuel pressure (measured at the port with the valve at the
air conditioning system compressor or at the reservoir) in bar
overpressure.
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
• Required cooling output is not at‐
tained.

• High pressure normal

• Low pressure too low (see graph)
• Required cooling output is not at‐
tained.

Note

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

flushing with refrigerant R134a ⇒ page 116 or blowing out with
compressed air and nitrogen ⇒ page 108 ).

8. Checking pressures 217

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Possible deviation from specification Possible causes of fault Fault elimination

• High pressure does not increase ♦ No actuation of the air condi‐– Check actuation and drive of the
or only to 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 decrease ♦ The air conditioner compressor conditioner compressor (vehi‐
or only slightly. is not driven. cle-specific Workshop Manual).
• Required cooling output is not at‐
tained.

♦ Constriction or blockage in the – Clean refrigerant circuit (flush

refrigerant circuit (e.g. in the re‐ with refrigerant R134a
frigerant pipe between the ⇒ page 116 or blow out with
“low-pressure end” service compressed air and nitrogen
connection and the air condi‐ ⇒ page 108 ).
tioner compressor).
– Renew hose or pipe if kinked or
constricted.
♦ The air conditioner compressor – Renew air conditioner compres‐
is defective. sor.

Possible deviation from specification Possible causes of fault Fault elimination

• High pressure increases above Constriction or obstruction in re‐ – Feel the refrigerant circuit to
specification frigerant circuit check for a drop in tempera‐
ture⇒ Heating, air conditioning;
• Low pressure quickly drops to Rep. gr. 87 ; Refrigerant circuit;
value in graph or below System overview - Refrigerant
• Required cooling output is not at‐ circuit (vehicle-specific Work‐
tained. shop Manual).

• If difference in temperature is
found at one component:
– Renew hose or pipe if kinked or
constricted.

– In the event of clogging, clean

refrigerant circuit (flush with re‐
frigerant R134a ⇒ page 116 or
blow out with compressed air
and nitrogen ⇒ page 108 ).
• If no fault is found:
– Clean refrigerant circuit (flush
with refrigerant R134a
⇒ page 116 or blow out with
compressed air and nitrogen
⇒ page 108 ).
• 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‐
• After some time, high pressure ant circuit for min. 3 hours (see
increases above specification note)
and
• Low pressure drops to value in – Clean refrigerant circuit (flush
graph or below with refrigerant R134a
⇒ page 116 or blow out with
• Required cooling output is no lon‐ compressed air and nitrogen
ger attained. ⇒ page 108 ).

218 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
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Possible deviation from specification Possible causes of fault Fault elimination

• High and low pressure normal at
first.
• After lengthy operating period,
low pressure drops excessively
(evaporator ices up)

Note

♦ If a problem involving moisture in the refrigerant circuit only

occurs after a lengthy operating period or only infrequently
(low pressure drops below specification and evaporator ices
up), it is sufficient to renew the dryer (adjust the 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 116 or blow out with com‐
pressed air and nitrogen ⇒ page 108 ) when this problem
occurs. Normally, there is only a small quantity of moisture in
the system which can be removed by lengthy evacuation.

Possible deviation from specification Possible causes of fault Fault elimination

• High pressure normal The air conditioner compressor is defective. – Clean refrigerant cir‐
cuit (flush with refrig‐
• Low pressure too low (see graph) erant R134a
• The required refrigeration capaci‐ ⇒ page 116 or blow
ty is attained. out with compressed
air and nitrogen
⇒ page 108 ).

– 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 air conditioner com‐
pressor being shut off by operating and display unit (if tem‐
perature at fresh air blower drops below -3 ｰC) ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - Refrigerant circuit or ⇒ Heating, air conditioning; Rep.
gr. 87 (vehicle-specific Workshop Manual).

8. Checking pressures 219

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Possible deviation from specification Possible causes of fault Fault elimination

• High pressure normal or too high Too much refrigerant in the circuit. – Extract refrigerant
from refrigerant cir‐
• Low pressure too high (see cuit.
graph)
• Air conditioner compressor noise • If quantity of refriger‐
(particularly after switch-on), ant extracted roughly
corresponds to
• Required cooling output is not at‐ specified capacity:
tained.
– Renew the air condi‐
tioning system com‐
pressor.

• The quantity of re‐

frigerant extracted is
substantially greater
than the specified
capacity.
– Re-charge refriger‐
ant circuit.

– Repeat test.

Possible deviation from specification Possible causes of fault Fault elimination

• High and low pressure normal Too much refrigerant oil in the circuit. – Discharge refriger‐
ant circuit.
• Required cooling output is not at‐
tained. – Clean refrigerant
circuit (flush with re‐
frigerant R134a
⇒ page 116 or blow
out with com‐
pressed air and ni‐
trogen
⇒ page 108 ).
• High and low pressure normal
• Air conditioner compressor noise
(particularly after switch-on),
• The required refrigeration capaci‐
ty is attained.

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, drain the air
conditioner compressor and renew the reservoir. After clean‐
ing the refrigerant circuit (flush with refrigerant R134a
⇒ page 116 or blow out with compressed air and nitrogen
⇒ page 108 ), add the correct amount of refrigerant oil to the
circuit ⇒ page 332 .

8.3 Checking pressures on vehicles with an

expansion valve and receiver (with in‐

220 Rep. gr.87 - Air conditioning system

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Air conditioner with refrigerant R134a - Edition 11.2014

ternally regulated air conditioner com‐

pressor)

Note

♦ Connect air conditioner service station ⇒ page 198 .

♦ Observe test requirements ⇒ page 206 .

– Check the pressures in the refrigerant circuit (with the air con‐
ditioner service station) with the ignition switched off
⇒ page 211 .
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
conditioner service station.

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,
air conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - Refrigerant circuit (vehicle-specific Workshop Manual).

⇒ “8.3.1 Specifications for pressures in refrigerant circuit”,

page 221

8.3.1 Specifications for pressures in refriger‐

8. Checking pressures 221

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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
– Localise leak with leak detector and
• Required cooling output eliminate
is not attained.
– Re-charge refrigerant circuit.

– 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 116 or blow out with compressed air
and nitrogen ⇒ page 108 ).

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 increase er compressor tioner compressor
or only to (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 de‐
crease or
only slightly.
• Required
cooling out‐
put is not at‐
tained.

222 Rep. gr.87 - Air conditioning system

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Possible devia‐ Possible causes of Fault elimination

tion from speci‐ fault
fication
♦ Constriction or – Clean refrigerant cir‐
blockage in the cuit (flush with refrig‐
refrigerant circuit erant R134a
(e.g. in the refrig‐ ⇒ page 116 or blow
erant pipe be‐ out with compressed
tween the “low- air and nitrogen
pressure end” ⇒ page 108 ).
service connec‐
tion and the air – Renew hose or pipe if
conditioner com‐ kinked or constricted.
pressor).

♦ The air condi‐ – Renew air condition‐

tioner compres‐ er compressor.
sor is defective.

Possible deviation from Possible causes of fault Fault elimination

specification
• High pressure increases ♦ Constriction or obstruction in refrig‐ – Feel the refrigerant circuit to check
above specification erant circuit for a drop in temperature⇒ Heating,
air conditioning; Rep. gr. 87 ; Re‐
• Low pressure quickly ♦ Expansion valve defective frigerant circuit; System overview -
drops to value in graph Refrigerant circuit (vehicle-specific
or below Workshop Manual).
• Required cooling output
is not attained. • If difference in temperature is found
at one component:
– Renew hose or pipe if kinked or
constricted.

– In the event of clogging, clean the

refrigerant circuit (flush with refrig‐
erant R134a ⇒ page 116 or blow out
with compressed air and nitrogen
⇒ page 108 and renew the expan‐
sion valve if applicable).
• If no fault is found:
– Clean the refrigerant circuit (flush
with refrigerant R134a ⇒ page 116
or blow out with compressed air and
nitrogen ⇒ page 108 and renew the
expansion valve if applicable).

– Repeat test.

Note

If operation is not OK after cleaning the refrigerant circuit (flush

with refrigerant R134a ⇒ page 116 or blow out with compressed
air and nitrogen ⇒ page 108 ), the expansion valve must be re‐
newed.

8. Checking pressures 223

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Possible deviation from Possible causes of fault Fault elimination

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 116 or
is no longer attained. blow out with compressed air and
nitrogen ⇒ page 108 ).
• High and low pressure
normal at first
• After lengthy operating
period, low pressure
drops excessively
(evaporator ices up)

Note

♦ It is not initially necessary to clean the refrigerant circuit (flush

Possible deviation from specifica‐ Possible causes of fault Fault elimination

tion
• High pressure normal or too ♦ Too much refrigerant in the – Extract refrigerant from refrigerant
high circuit. circuit.
• Low pressure too high (see ♦ Expansion valve or air condi‐ • If quantity of refrigerant extracted
graph) tioner compressor defective. 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.
– Re-charge refrigerant circuit.

– Repeat test.

224 Rep. gr.87 - Air conditioning system

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Air conditioner with refrigerant R134a - Edition 11.2014

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 116 or blow out
with compressed air and nitrogen ⇒ page 108 ). Then renew the
air conditioner compressor and receiver.

Possible deviation from specifica‐ Possible causes of fault Fault elimination

tion
• High pressure only increases The air conditioner compressor is – Clean refrigerant circuit (flush with
slightly above pressure with defective. refrigerant R134a ⇒ page 116 or
engine stopped blow out with compressed air and
nitrogen ⇒ page 108 ).
• Low pressure only drops slight‐
ly – Renew the air conditioner com‐
• Required cooling output is not pressor and receiver.
attained.

Possible deviation from specifica‐ Possible causes of fault Fault elimination

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)
• The required refrigeration ca‐ – Repeat test.
pacity is attained.

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 116 or
blow out with compressed air and nitrogen ⇒ page 108 ). Then
renew the air conditioner compressor and receiver.
♦ In this case, the evaporator may ice up although the correct
quantity of refrigerant is present in the refrigerant circuit.

Possible deviation from specifica‐ Possible causes of fault Fault elimination

tion
• High and low pressure normal Too much refrigerant oil in the cir‐ – Discharge refrigerant circuit.
cuit.
• Required cooling output is not – Clean refrigerant circuit (flush with
attained. refrigerant R134a ⇒ page 116 or
blow out with compressed air and
nitrogen ⇒ page 108 ).

8. Checking pressures 225

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Possible deviation from specifica‐ Possible causes of fault Fault elimination

tion
• High and low pressure normal
• Air conditioner compressor
noise (particularly after switch-
on),
• The required refrigeration ca‐
pacity is attained.

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, drain the air
conditioner compressor and renew the receiver. After cleaning
the refrigerant circuit (flush with refrigerant R134a
⇒ page 116 or blow out with compressed air and nitrogen
⇒ page 108 ), add the correct amount of refrigerant oil to the
circuit ⇒ page 332 .

8.4 Checking pressures on vehicles with re‐

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

Note

♦ Connect air conditioner service station ⇒ page 198 .

♦ Observe test requirements ⇒ page 206 .

– Check the pressures in the refrigerant circuit (with the air con‐
ditioner service station) with the ignition switched off
⇒ page 211 .
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
conditioner service station.

Note

♦ The switching pressures for actuation of -N280- and the radi‐

ator fans - V7- are vehicle-specific.
♦ Measure the pressures at the service connections; the fitting
locations of these connections are vehicle-specific ⇒ Heating,
air conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - Refrigerant circuit (vehicle-specific Workshop Manual).

226 Rep. gr.87 - Air conditioning system

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⇒ “8.4.1 Specifications for pressures in refrigerant circuit”,

page 227

8.4.1 Specifications for pressures in refriger‐

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

8. Checking pressures 227

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Low-pressure side:
Decreasing from initial pressure (on connecting pressure gauges)
to value in graph
A - Low pressure (measured at service connection) in bar abso‐
lute
B - Control current for air conditioner compressor regulating valve
- N280- in amps
C - Permissible tolerance range

228 Rep. gr.87 - Air conditioning system

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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 side 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 side
to the value in the graph. One way of checking the control ac‐
tion of the air conditioner compressor under these conditions
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 (“self-di‐
agnosis” or “Guided Fault Finding” function for air conditioner)
and ⇒ Heating, air conditioning; Rep. gr. 00 ; Repair instruc‐
tions; Checking the cooling output or ⇒ Heating, air condi‐
tioning; Rep. gr. 87 (vehicle-specific Workshop Manual).
♦ Under unfavourable conditions (very high ambient tempera‐
tures, high humidity), pressure in high-pressure side may in‐
crease to max. 29 bar.
♦ The control current -B- is displayed in the measured value
block of the operating and display unit for Climatronic air con‐
ditioning system - E87- or the 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 the operating and display unit for Climatronic air con‐
ditioning system - E87- or the operating and display unit,
Climatronic control unit - J255- ⇒ Vehicle diagnostic tester
(“self-diagnosis” or “Guided Fault Finding” function for air con‐
ditioner) and ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐
frigerant circuit; System overview - Refrigerant circuit (vehicle-
specific Workshop Manual).
♦ 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.
♦ Under unfavourable conditions (very high ambient tempera‐
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 side 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 1 bar absolute. 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”).

8. Checking pressures 229

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

regulated to approx. 0.65 (vehicle-specific up to 0.85 A) (dis‐
played in measured value block) ⇒ Vehicle diagnostic tester
(“self-diagnosis” or “Guided Fault Finding” function for air con‐
ditioner) and ⇒ Heating, air conditioning; Rep. gr. 00 ; Repair
instructions; Checking the cooling output or ⇒ Heating, air
conditioning; Rep. gr. 87 (vehicle-specific Workshop Manual).

Possible deviation from Possible causes of fault Fault elimination

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

• High pressure normal

• Low pressure too low
(see graph)
• Required cooling output
is not attained.

• High pressure normal

• 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

flushing with refrigerant R134a ⇒ page 116 or blowing out with
compressed air and nitrogen ⇒ page 108 ).

Possible deviation from spec‐ Possible causes of fault Fault elimination

ification
• High pressure does not in‐ ♦ No actuation of the air conditioner – Check actuation and drive of the air
crease or only to 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 de‐ ♦ The air conditioner compressor is Manual).
crease or only slightly. not driven.
• Required cooling output is – Check actuation and operation of -
not attained. N280- .

230 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Possible deviation from spec‐ Possible causes of fault Fault elimination

ification
♦ Constriction or blockage in the re‐ – Clean refrigerant circuit (flush with
frigerant circuit (e.g. in the refrig‐ refrigerant R134a ⇒ page 116 or
erant pipe between the “low- blow out with compressed air and ni‐
pressure end” service connection trogen ⇒ page 108 ).
and the air conditioner compres‐
sor). – 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 289 .
♦ The air conditioner compressor is – Renew air conditioner compressor.
defective.

Possible deviation from spec‐ Possible causes of fault Fault elimination

ification
• High pressure increases ♦ Actuation of air conditioner com‐ – Checking activation of the -N280- ⇒
above specification pressor regulating valve - N280- Heating, air conditioning; Rep. gr.
not OK 87 ; Refrigerant circuit; System over‐
• Low pressure quickly view - Refrigerant circuit (vehicle-
drops to value in graph or ♦ Constriction or obstruction in re‐ specific Workshop Manual).
below frigerant circuit
• Required cooling output is – Run hand over refrigerant circuit to
not attained. check for differences in temperature

• If difference in temperature is found

at one component:
– Renew hose or pipe if kinked or con‐
stricted.

– Flush the refrigerant circuit with com‐

pressed air and nitrogen in the event
of an obstruction.

• If no fault is found:
– Clean refrigerant circuit (flush with
refrigerant R134a ⇒ page 116 or
blow out with compressed air and ni‐
trogen ⇒ page 108 ).

Possible deviation from spec‐ Possible causes of fault Fault elimination

ification
• High and low pressure ♦ Actuation of air conditioner com‐ – Checking activation of the -N280- ⇒
normal at first, after some pressor regulating valve - N280- Heating, air conditioning; Rep. gr.
time high pressure increa‐ not OK 87 ; Refrigerant circuit; System over‐
ses above specification view - Refrigerant circuit (vehicle-
and specific Workshop Manual).
• Low pressure drops to val‐ – Renew reservoir (with dryer) and
ue in graph or below evacuate refrigerant circuit for at
• Required cooling output is least 3 hours (see note)
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
contamination ⇒ page 289 .

8. Checking pressures 231

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Possible deviation from spec‐ Possible causes of fault Fault elimination

ification
• After lengthy operating pe‐ ♦ Moisture in refrigerant circuit – Clean refrigerant circuit (flush with
riod, low pressure drops refrigerant R134a ⇒ page 116 or
excessively (evaporator blow out with compressed air and ni‐
ices up) trogen ⇒ page 108 ).

Note

♦ It is not initially necessary to clean the refrigerant circuit (flush

with refrigerant R134a ⇒ page 116 or blow out with com‐
pressed air and nitrogen ⇒ page 108 ) when this problem
occurs. Normally, there is only a small quantity of moisture in
the system which can be removed by lengthy evacuation.
♦ If a problem involving moisture in the refrigerant circuit only
occurs after a lengthy operating period or only infrequently
(low pressure drops below specification and evaporator ices
up), it is sufficient to renew the dryer (adjust the 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 is
encountered, also pay attention to 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 the cooling output
or ⇒ Heating, air conditioning; Rep. gr. 87 (vehicle-specific
Workshop Manual).

Possible deviation from spec‐ Possible causes of fault Fault elimination

ification
• High pressure normal ♦ Actuation of air conditioner com‐ – Checking activation of the -N280- ⇒
pressor regulating valve - N280- Heating, air conditioning; Rep. gr.
• Low pressure too low (see not OK 87 ; Refrigerant circuit; System
graph) overview - Refrigerant circuit (vehi‐
♦ Air conditioner compressor regu‐ cle-specific Workshop Manual).
• The required refrigeration lating valve - N280- defective
capacity is attained.
– Check operation of -N280- , remove
-N280- if applicable and check for
contamination ⇒ page 289 .
♦ The air conditioner compressor is – Clean refrigerant circuit (flush with
defective. refrigerant R134a ⇒ page 116 or
blow out with compressed air and
nitrogen ⇒ page 108 ).
– Renew air conditioner compressor.

232 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

Observe the following with regard to fault “High pressure normal,

low pressure too low”: This fault may cause evaporator to ice up
although quantity of refrigerant in circuit is OK. Check measured
values of evaporator output temperature sender - G263- and ac‐
tuation 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 out‐
put is not attained ⇒ Vehicle diagnostic tester (“self-diagnosis” or
“Guided Fault Finding” function for air conditioner) and ⇒ Heating,
air conditioning; Rep. gr. 00 ; Repair instructions; Checking the
cooling output or ⇒ Air conditioning; Rep. gr. 87 (vehicle-specific
Workshop Manual).

Possible deviation from spec‐ Possible causes of fault Fault elimination

ification
• High pressure normal or ♦ Actuation of air conditioner compressor – Checking activation of the -
too high regulating valve - N280- not OK N280- ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrig‐
• Low pressure too high ♦ Too much refrigerant in the circuit. erant circuit; System overview
(see graph) - Refrigerant circuit (vehicle-
• Air conditioner compres‐ specific Workshop Manual).
sor noise (particularly after
switch-on), – Extract refrigerant from refrig‐
erant circuit.
• Required cooling output is
not attained. • If quantity of refrigerant ex‐
tracted roughly corresponds
to specified capacity:
– Renew the air conditioning
system compressor.

• The quantity of refrigerant ex‐

tracted is significantly greater
than the prescribed charge
quantity.
– Re-charge refrigerant circuit.

– 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 the circuit.
not attained.

• High pressure and low – Clean refrigerant circuit (flush

pressure are normal. with refrigerant R134a
⇒ page 116 or blow out with
• Air conditioner compres‐ compressed air and nitrogen
sor noise (particularly after ⇒ page 108 ).
switch-on).
• The required refrigeration
capacity is attained.

8. Checking pressures 233

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

8.5 Checking pressures on vehicles with ex‐

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

Note

♦ Connect air conditioner service station ⇒ page 198 .

♦ Observe test requirements ⇒ page 206 .
♦ 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 the line connection between the prob‐
lematic evaporator and the outgoing line connection at the
refrigerant line distribution 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 conditioner again. If the problem persists, renew the
expansion valve upstream of the problematic evaporator ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - refrigerant circuit (vehicle-specific Work‐
shop Manual).

– Check the pressures in the refrigerant circuit (with the air con‐
ditioner service station) with the ignition switched off
⇒ page 211 .
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
conditioner service station.

234 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

♦ The switching pressures for actuation of the air conditioner

compressor regulating valve - N280- and the radiator fans -
V7- are vehicle-specific.
♦ Measure the pressures at the service connections; the fitting
locations of these connections are vehicle-specific ⇒ Heating,
air conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - Refrigerant circuit (vehicle-specific Workshop Manual).

⇒ “8.5.1 Specifications for pressures in refrigerant circuit”,

page 235

8.5.1 Specifications for pressures in refriger‐

ant circuit
High-pressure side:
Increasing from initial pressure (on connecting pressure gauges)
up to max. 20 bar

8. Checking pressures 235

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Low pressure:
Decreasing from initial pressure (on connecting pressure gauges)
to value in graph
A - Low pressure (measured at service connection) in bar abso‐
lute
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 %).

236 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 side 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 side
to the value in the graph. One way of checking the control ac‐
tion of the air conditioner compressor under these conditions
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 (“self-di‐
agnosis” or “Guided Fault Finding” function for air conditioner)
and ⇒ Heating, air conditioning; Rep. gr. 00 ; Repair instruc‐
tions; Checking the cooling output or ⇒ Heating, air condi‐
tioning; Rep. gr. 87 (vehicle-specific Workshop Manual).
♦ Under unfavourable conditions (very high ambient tempera‐
tures, high humidity), the pressure on the high-pressure side
may increase up to max. 29 bar.
♦ The control current -B- is displayed in the measured value
block of the operating and display unit for Climatronic air con‐
ditioning system - E87- or the Climatronic control unit - J255- .
♦ The high pressure measured by the high-pressure sender -
G65- (or the refrigerant pressure and temperature sender -
G395- or the refrigerant pressure sender - G805- ) is displayed
as a measured value (from the operating and display unit for
air conditioning system - E87- and the control unit for air con‐
ditioning system - J301- or the operating and display unit and
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.
♦ Under unfavourable conditions (very high ambient tempera‐
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 side 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.

8. Checking pressures 237

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

♦ On the absolute pressure scale, 0 bar corresponds to an ab‐

solute vacuum. Normal ambient pressure corresponds to 1 bar
absolute. On the scales of most pressure gauges, 0 bar cor‐
responds to an absolute pressure of 1 bar (can be seen from
-1 bar mark below 0) ⇒ Vehicle diagnostic tester (“self-diag‐
nosis” or “Guided Fault Finding” function for air conditioner)
and ⇒ Heating, air conditioning; Rep. gr. 00 ; Repair instruc‐
tions; Checking the cooling output or ⇒ Heating, air condi‐
tioning; Rep. gr. 87 (vehicle-specific Workshop Manual).

Possible deviation from speci‐ Possible causes of fault Fault elimination

fication
• High pressure remains con‐ ♦ Actuation of air conditioner compres‐ – Checking activation of the -
stant or only increases sor regulating valve - N280- not OK N280- ⇒ Heating, air condi‐
slightly (above pressure tioning; Rep. gr. 87 ; Refrig‐
with engine stopped) ♦ Not enough refrigerant in circuit erant circuit; System over‐
view - Refrigerant circuit
• Low pressure quickly drops ♦ Expansion valve defective (vehicle-specific Workshop
to value in graph or below Manual).
• Required cooling output is
not attained. – Extract refrigerant from re‐
frigerant circuit.

• If quantity of refrigerant ex‐

tracted is substantially less
than specified capacity:

• High pressure normal – Localise leak with leak de‐

tector and eliminate
• Low pressure in line with
value in graph – Re-charge refrigerant circuit.
• Required cooling output is
not attained. – Repeat test.

• High pressure normal • If quantity of refrigerant ex‐

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

– Repeat test.

238 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

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

flushing with refrigerant R134a ⇒ page 116 or blowing out with
compressed air and nitrogen ⇒ page 108 ).
♦ 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 116 or blow out with compressed air
and nitrogen ⇒ page 108 ). Then renew the air conditioner
compressor and receiver.
♦ In this case, the evaporator may ice up although the correct
quantity of refrigerant is present in the refrigerant circuit.
♦ 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 side). As however 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 no energy exchange is taking place ⇒ Vehicle
diagnostic tester (“self-diagnosis” or “Guided Fault Finding”
function for air conditioner) and ⇒ Heating, air conditioning;
Rep. gr. 00 ; Repair instructions; Checking the cooling output
or ⇒ Heating, air conditioning; Rep. gr. 87 (vehicle-specific
Workshop Manual).

Possible devia‐ Possible causes of Fault elimination

tion from specifi‐ fault
cation
• High pres‐ ♦ No actuation of – Check actuation
sure does not the air condition‐ and drive of the air
increase or er compressor conditioner com‐
only to slight‐ ( air conditioner pressor and per‐
ly 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 de‐ not driven. Manual).
crease or on‐
ly 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 289 .

8. Checking pressures 239

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Possible devia‐ Possible causes of Fault elimination

tion from specifi‐ fault
cation
♦ Constriction or – Clean refrigerant
blockage in the circuit (flush with re‐
refrigerant circuit frigerant R134a
(e.g. in the refrig‐ ⇒ page 116 or blow
erant pipe be‐ out with com‐
tween the “low- pressed air and ni‐
pressure end” trogen
service connec‐ ⇒ page 108 ).
tion and the air
conditioner com‐ – Renew hose or pipe
pressor). if kinked or constric‐
ted.
♦ The air condition‐ – Renew air condi‐
er compressor is tioner compressor.
defective.

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
⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐
pressor (vehicle-specific Workshop Manual) and ⇒ Electronic
parts catalogue .

240 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Possible deviation from spec‐ Possible causes of fault Fault elimination

ification
• High pressure increases ♦ Actuation of air conditioner com‐ – Checking activation of the -N280- ⇒
above specification pressor regulating valve - N280- Heating, air conditioning; Rep. gr.
not OK 87 ; Refrigerant circuit; System over‐
• Low pressure quickly view - Refrigerant circuit (vehicle-
drops to value in graph ♦ Constriction or obstruction in re‐ specific Workshop Manual).
frigerant circuit
• Required cooling output is
not attained ♦ Expansion valve defective – Run hand over refrigerant circuit to
check for differences in temperature

• If difference in temperature is found

at one component:
– Renew hose or pipe if kinked or con‐
stricted.
– In the event of clogging, clean refrig‐
erant circuit (flush with refrigerant
R134a ⇒ page 116 or blow out with
compressed air and nitrogen
⇒ page 108 ).

– Re-charge refrigerant circuit.

– Repeat test.

• If no fault is found:
– Clean refrigerant circuit (flush with
refrigerant R134a ⇒ page 116 or
blow out with compressed air and ni‐
trogen ⇒ page 108 ).

– Re-charge refrigerant circuit.

– If function is not OK, repeat test:

– Renew expansion valve and receiv‐

er.

8. Checking pressures 241

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

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

the test is repeated, renew expansion valve and receiver.
♦ With this fault, the evaporator may ice up although the quantity
of refrigerant in the circuit is OK.
♦ If the expansion valve is defective (permanently closed or
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 side). As however 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
no energy exchange is taking place ⇒ Vehicle diagnostic test‐
er (“self-diagnosis” or “Guided Fault Finding” function for air
conditioner) and ⇒ Heating, air conditioning; Rep. gr. 00 ;
Repair instructions; Checking the cooling output or ⇒ Heating,
air conditioning; Rep. gr. 87 (vehicle-specific Workshop Man‐
ual).
♦ If there is too much refrigerant oil in the circuit, drain the air
conditioner compressor and renew the receiver. After cleaning
the refrigerant circuit (flush with refrigerant R134a
⇒ page 116 or blow out with compressed air and nitrogen
⇒ page 108 ), add the correct amount of refrigerant oil to the
circuit ⇒ page 332 .

Possible deviation from speci‐ Possible causes of fault Fault elimination

fication
• High and low pressure nor‐ ♦ Actuation of air conditioner compres‐ – Checking activation of the -
mal at first sor regulating valve - N280- not OK N280- ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrig‐
• After some time, high pres‐ ♦ Moisture in refrigerant circuit erant circuit; System over‐
sure increases above spec‐ view - Refrigerant circuit
ification and (vehicle-specific Workshop
• Low pressure drops to val‐ Manual).
ue in graph or below
– Clean refrigerant circuit
• Required cooling output is (flush with refrigerant R134a
no longer attained. ⇒ page 116 or blow out with
compressed air and nitrogen
⇒ page 108 ).
• 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 289 .

242 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

♦ It is not initially necessary to clean the refrigerant circuit (flush

with refrigerant R134a ⇒ page 116 or blow out with com‐
pressed air and nitrogen ⇒ page 108 ) when this problem
occurs. Normally, there is only a small quantity of moisture in
the system which can be removed by lengthy evacuation.
♦ If a problem involving moisture in the refrigerant circuit only
occurs after a lengthy operating period or only infrequently
(low pressure drops below specification and evaporator ices
up), it is sufficient to renew the dryer in the receiver (adjust
quantity of refrigerant oil). Subsequently, evacuate refrigerant
circuit for at least 3 hours.
♦ In this case, the evaporator may ice up although the correct
quantity of refrigerant is present in the refrigerant circuit.
♦ A problem with evaporator output temperature sender - G263-
can also cause icing-up of refrigerant circuit. If this problem is
encountered, also pay attention to 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 the cooling output
or ⇒ Heating, air conditioning; Rep. gr. 87 (vehicle-specific
Workshop Manual).

Possible deviation from speci‐ Possible causes of fault Fault elimination

fication
• High pressure normal ♦ Actuation of air conditioner compres‐ – Checking activation of the -
sor regulating valve - N280- not OK N280- ⇒ Heating, air condi‐
• Low pressure too low (see tioning; Rep. gr. 87 ; Refrig‐
graph) erant circuit; System over‐
• The required refrigeration view - Refrigerant circuit
capacity is attained. (vehicle-specific Workshop
Manual).

– Clean refrigerant circuit

(flush with refrigerant R134a
⇒ page 116 or blow out with
compressed air and nitrogen
⇒ page 108 ) (not always
necessary, refer to notes).
♦ Air conditioner compressor regulating – Check operation of -N280- ,
valve - N280- defective remove -N280- if applicable
and check for contamination
⇒ page 289 .
♦ Expansion valve or air conditioner – Renew expansion valve and
compressor defective. receiver.
♦ The air conditioner compressor is de‐ – Re-charge refrigerant circuit.
fective.
– If function is not OK, repeat
test:

– Renew air conditioner com‐

pressor.

– Re-charge refrigerant circuit.

– Repeat test.

8. Checking pressures 243

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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
flushing with refrigerant R134a ⇒ page 116 or blowing out with
compressed air and nitrogen ⇒ page 108 ). In this case it is
sufficient to renew the air conditioner compressor (observe
quantity of refrigerant oil in compressor).
♦ 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 side). As refrigerant cannot however
flow via the expansion valve, the cooling output is not attained
and the 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 is
not attained ⇒ Vehicle diagnostic tester (“self-diagnosis” or
“Guided Fault Finding” function for air conditioner) and ⇒
Heating, air conditioning; Rep. gr. 00 ; Repair instructions;
Checking the cooling output or ⇒ Heating, air conditioning;
Rep. gr. 87 (vehicle-specific Workshop Manual).

244 Rep. gr.87 - Air conditioning system

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Possible deviation from speci‐ Possible causes of fault Fault elimination

fication
• High pressure normal or too ♦ Actuation of air conditioner compres‐– Checking activation of the -
high sor regulating valve - N280- not OK N280- ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrig‐
• Low pressure too high (see ♦ Too much refrigerant in the circuit. erant circuit; System over‐
graph) view - Refrigerant circuit
♦ Expansion valve defective
• Air conditioner compressor (vehicle-specific Workshop
noise (particularly after ♦ The air conditioner compressor is de‐ Manual).
switch-on), fective.
– Extract refrigerant from re‐
• The required refrigeration frigerant circuit.
capacity is attained.
• The quantity of refrigerant
extracted roughly corre‐
sponds to the actual capaci‐
ty.
– Renew expansion valve and
receiver.

– Re-charge refrigerant circuit.

– If function is not OK, repeat

test:

– Renew the air conditioning

system compressor.

• If quantity of refrigerant ex‐

tracted is substantially great‐
er than specified capacity:
– Re-charge refrigerant circuit.

– 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.
♦ 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 side). As however 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 no energy exchange is taking place ⇒ Vehicle
diagnostic tester (“self-diagnosis” or “Guided Fault Finding”
function for air conditioner) and ⇒ Heating, air conditioning;
Rep. gr. 00 ; Repair instructions; Checking the cooling output
or ⇒ Heating, air conditioning; Rep. gr. 87 (vehicle-specific
Workshop Manual).

8. Checking pressures 245

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Possible deviation from speci‐ Possible causes of fault Fault elimination

fication
• High and low pressure nor‐ ♦ Actuation of air conditioner compres‐ – Checking activation of the -
mal sor regulating valve - N280- not OK N280- ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrig‐
• The required refrigeration ♦ Too much refrigerant in the circuit. erant circuit; System over‐
capacity is attained. view - Refrigerant circuit
♦ Expansion valve defective
(vehicle-specific Workshop
Manual).

– Discharge refrigerant circuit.

– Clean refrigerant circuit

– Renew expansion valve.

– Re-charge refrigerant circuit.

– Repeat test.

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 the expansion valve is defective (permanently open), the
evaporator temperature is no longer regulated so that only re‐
frigerant in gas form exits from the evaporator. Under certain
usage conditions, liquid droplets may then be drawn in by the
air conditioner compressor and cause noise (liquid cannot be
compressed).
♦ If there is too much refrigerant oil in the circuit, drain the air
conditioner compressor and renew the receiver. After cleaning
the refrigerant circuit (flush with refrigerant R134a
⇒ page 116 or blow out with compressed air and nitrogen
⇒ page 108 ), add the correct amount of refrigerant oil to the
circuit ⇒ page 332 .

8.6 Checking pressures on vehicles with an

electrically driven air conditioner com‐
pressor (vehicles with a high-voltage
system)
For all work on vehicles with a high-voltage system, note the ad‐
ditional warning instructions for working on such vehicles
⇒ “1 Warning instructions when working on vehicles with high-
voltage system”, page 1 and ⇒ Electrical system; Rep. gr. 93 ;
General warning instructions for work on the high-voltage sys‐
tem .

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WARNING

Safety hazard: the engine can start unexpectedly.

Before carrying out general work on a vehicle with high-voltage
electrical system, switch off the ignition and remove the ignition
key from the vehicle.

WARNING

Working on vehicles with high-voltage wiring:

DANGER!

Risk of fatal injury if high-voltage components are damaged.

8. Checking pressures 247

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If work is necessary in the vicinity of high-voltage system com‐

Note

The work on the refrigerant circuit using the air conditioner service
station (here: checking pressure) described in the following can
only be carried out when the vehicle's drive system is active; if
necessary, re-energise the high-voltage system.

Re-energising high-voltage system

DANGER!

High voltage can cause fatal injury.

Note

♦ Re-energising high-voltage system:

248 Rep. gr.87 - Air conditioning system

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DANGER!

When working on a vehicle with the ignition switched on or

– To minimise the number of automatic engine starts when the

Note

– Switch off ignition.

8. Checking pressures 249

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⇒ “7 Connecting air conditioner service station ”, page 198

⇒ “8 Checking pressures”, page 206

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 com‐
ponents: 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. the -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 the -N516- / -N541- . If the problem
only occurs on the evaporator for cooling the high-voltage com‐
ponents (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 oc‐
curs on the heat exchanger for high-voltage battery, check shut-
off valve -N542- (when not activated, it is open and allows the
refrigerant to flow through) and the restrictor integrated in the re‐
frigerant line ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit; System overview - Refrigerant circuit (vehicle-specific
Workshop Manual).

– Check the pressures in the refrigerant circuit (with the air con‐
ditioner service station) with the ignition switched off
⇒ page 211 .
The pressures with the ignition switched off correspond to the
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 .

250 Rep. gr.87 - Air conditioning system

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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 the air conditioner.
– Observe the pressure reading (e.g. pressure gauge) of the air
conditioner service station.

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
vehicle speed of approx. 45 km /h), the air conditioner com‐
pressor is not actuated at the maximum specified speed (of
approx. 8500 rpm) (the air conditioner compressor speed is
limited to approx. 5000 rpm).
♦ Actuation of the electrically driven air conditioner compressor
can be monitored by way of the Guided Fault Finding routine
⇒ Vehicle diagnostic tester, “Guided Fault Finding” function
for air conditioner and battery regulation
♦ Measure the pressures at the service connections; the fitting
locations of these connections are vehicle-specific ⇒ Heating,
air conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - Refrigerant circuit (vehicle-specific Workshop Manual).

⇒ “8.6.1 Specifications for pressures in refrigerant circuit”,

page 251

8.6.1 Specifications for pressures in refriger‐

ant circuit
High-pressure side:
Increasing from initial pressure (on connecting pressure gauges)
up to max. 20 bar
Low-pressure side:
Dropping from initial pressure (on connecting pressure gauges)
to a value between 1.5 and 2.3 bar absolute (depending on cool‐
ing output required).
Air conditioner compressor speed:
Between 800 and 8600 rpm depending on cooling output required
(currently max. 5000 rpm with vehicle stationary)

8. Checking pressures 251

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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 the operating and display unit, Climatronic
control unit - J255- ⇒ Vehicle diagnostic tester, “Guided Fault
Finding” function for air conditioner
♦ In the event of a very high cooling output requirement (e.g.
high ambient temperature and high fresh-air blower speed),
the air conditioner 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 stationary or only moving slowly (up to a vehicle
speed of approx. 45 km /h), the air conditioner compressor is
not actuated at the maximum specified speed (of approx. 8500
rpm) (the air conditioner compressor speed is limited to ap‐
prox. 5000 rpm). Limitation of the maximum permissible air
conditioner compressor speed is only cancelled as of a vehicle
speed of more then approx. 45 km/h. At an air conditioner
compressor speed of 5000 rpm, with a high ambient temper‐
ature and a high fresh air blower speed (unfavourable ambient
conditions), the output (delivery volume) of the air conditioner
compressor is not sufficient at first 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 conditions 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 diag‐
nostic 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-specific Workshop Manual).
♦ Under unfavourable conditions (very high ambient tempera‐
tures, high humidity), the pressure on the high-pressure side
may increase up to max. 29 bar.
♦ The specified speed of the air conditioner compressor is dis‐
played as measured value by the operating and display unit,
Climatronic control unit - J255- ⇒ Vehicle diagnostic tester,
“Guided Fault Finding” function for air conditioner .
♦ The high pressure measured by the refrigerant pressure and
temperature sender - G395- or refrigerant pressure sender -
G805- is displayed as a measured value from the operating
and display unit, Climatronic control unit - J255- ⇒ Vehicle
diagnostic tester in “Guided Fault Finding” mode for air con‐
ditioner and ⇒ Heating, air conditioning; Rep. gr. 00 ; Repair
instructions; Checking the 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 speed of the air conditioner compressor must
be greater 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 measured value by the operating
and display unit, Climatronic control unit - J255- ⇒ Vehicle
diagnostic tester, “Guided Fault Finding” function for air con‐
ditioner and battery regulation .

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♦ On the absolute pressure scale, 0 bar corresponds to an ab‐

solute vacuum. Normal ambient pressure corresponds to 1 bar
absolute. On the scale of most pressure gauges, 0 bar corre‐
sponds to an absolute pressure of 1 bar (can be seen from -1
bar mark below 0) ⇒ Vehicle diagnostic tester using the “Gui‐
ded Fault Finding” function for the air conditioner and ⇒
Heating, air conditioning; Rep. gr. 00 ; Repair instructions;
Checking the cooling output (vehicle-specific Workshop Man‐
ual).
♦ If, on a vehicle with two evaporators (one in the air conditioning
unit and one for cooling the high-voltage components e.g. in
the battery cooling module or heat exchanger for high-voltage
battery), the measured temperature corresponds to or is below
the specified value at one evaporator but the required speci‐
fied value is not attained at the other evaporator, the system
is controlled as follows: the relevant battery regulation control
unit (the -J840- or -J255- ) actuates the electric air conditioner
compressor - V470- at a higher speed via various other control
units (e.g. the power and control electronics for electric drive
- JX1- and the control unit for air conditioner 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, the relevant con‐
trol 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 condi‐
tioning; Rep. gr. 00 ; Repair instructions; Checking the cooling
output (vehicle-specific Workshop Manual).
♦ As the cooling output of the evaporator for cooling the high-
voltage battery (in the battery cooling module and heat ex‐
changer for high-voltage battery) is considerably less than that
of the evaporator in the air conditioning unit, the required tem‐
perature in the evaporator for cooling the high-voltage battery
may still be reached 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).

Possible deviation from speci‐ Possible causes of fault Fault elimination

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 quickly drops frigerant circuit.
to specified value or below. ♦ Not enough refrigerant in circuit
• The required cooling output ♦ Expansion valve for evaporator in air • If quantity of refrigerant ex‐
is not attained in the evap‐ conditioning unit defective. tracted is substantially less
orator in the air conditioning than specified capacity:
unit and in the evaporator ♦ Shut-off valve upstream of the evapo‐
for cooling the high-voltage rator in the air conditioning unit (e.g. - – Localise leak with leak de‐
N516- or -N541- ) faulty (blocked) tector and eliminate
components.
– Re-charge refrigerant circuit.

– Repeat test.

8. Checking pressures 253

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Possible deviation from speci‐ Possible causes of fault Fault elimination

fication
• High pressure normal • If quantity of refrigerant ex‐
tracted roughly corresponds
• low pressure corresponds to specified capacity:
to specified value,
– Check the function of the
• Required cooling output is shut-off valve upstream of
not attained. the evaporator in the air con‐
ditioning unit (e.g. -N516- or
-N541- )

– Renew expansion valve.

– Re-charge refrigerant circuit.

– Repeat test.

Note

Observe notes ⇒ page 256 .

Possible deviation from speci‐ Possible causes of fault Fault elimination

fication
On a vehicle without 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- ) conditioner, air conditioner compres‐ • If quantity of refrigerant ex‐
• High pressure normal sor and battery regulation . tracted is substantially less
than specified capacity:
• low pressure too low (below ♦ Not enough refrigerant in circuit
specified value) – Localise leak with leak de‐
♦ Expansion valve for evaporator in air tector and eliminate
• Required cooling output is conditioning unit defective.
not attained at evaporator in – Re-charge refrigerant circuit.
air conditioning unit.
– Repeat test.
• If quantity of refrigerant ex‐
tracted roughly corresponds
to specified capacity:
– Renew expansion valve for
evaporator in air conditioning
unit.

– Re-charge refrigerant circuit.

– Repeat test.

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Possible deviation from speci‐ Possible causes of fault Fault elimination

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- ) conditioner, air conditioner compres‐ • The quantity of refrigerant
• High pressure normal sor and battery regulation . extracted is much less than
the specified capacity (con‐
• low pressure too low (below ♦ Not enough refrigerant in circuit tinue in same way as a vehi‐
specified value) cle without a shut-off valve
♦ Expansion valve for evaporator in air
• The required cooling output conditioning unit defective. upstream of the evaporator
is not attained at the evap‐ in the air conditioning unit)
orator in the air conditioning ♦ Shut-off valve upstream of the evapo‐ • If quantity of refrigerant ex‐
unit and at the evaporator rator in the air conditioning unit (e.g. -
N516- or -N541- ) faulty (blocked) tracted roughly corresponds
for cooling the high-voltage to specified capacity:
components.
– Check actuation and opera‐
tion of the shut-off valve up‐
stream of the evaporator in
the air conditioning unit (e.g.
-N516- or -N541- ) and the
shut-off valve upstream of
the evaporator for cooling
the high-voltage compo‐
nents (e.g. -N517- or -
N542- )

– Renew expansion valve up‐

stream of evaporator in air
conditioning unit.

– Renew expansion valve (or

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

– Re-charge refrigerant circuit.

– Repeat test.

8. Checking pressures 255

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Note

♦ If no fault is found for this problem, clean the refrigerant circuit

(flush with refrigerant R134a ⇒ page 116 or blow out with
compressed air and nitrogen ⇒ page 108 ). Constriction or
blockage in the refrigerant circuit may also lead to one of these
problems.
♦ Check the measured values of the evaporator output temper‐
ature sender - G263- and, if fitted, of the temperature sensor
upstream of evaporator for hybrid battery - G756- and of the
temperature sensor downstream of evaporator for hybrid bat‐
tery - G757- as well as actuation of the air conditioner com‐
pressor by way of the relevant control units (e.g. the control
unit for air conditioning compressor - J842- by the battery reg‐
ulation control unit - J840- or the air conditioner operating and
display unit, the Climatronic control unit - J255- ) ⇒ Vehicle
diagnostic tester in “Guided Fault Finding function” mode for
air conditioner and battery regulation and ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting locations.
♦ An incorrect measured value from the -G263- (or e.g. the -
G756- or the -G757- ) can also cause problems with the
cooling power or the evaporator in the air conditioning unit may
ice up⇒ Vehicle diagnostic tester in “Guided Fault Finding”
mode for air conditioner and battery regulation .
♦ If, after renewing the expansion valve for example, operation
of the air conditioner is not OK when the test is repeated (re-
fit old expansion valve), clean the refrigerant circuit (flush with
refrigerant R134a ⇒ page 116 or blow out with compressed air
and nitrogen ⇒ page 108 ). Then renew the air conditioner
compressor and receiver/desiccant cartridge.
♦ In the event of a fault at a temperature sensor, 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- ) is defective (is permanently
closed or does not open sufficiently), the air conditioner com‐
pressor is actuated to maximum output and the low pressure
drops to the value in the graph or below (air conditioner com‐
pressor draws off refrigerant from low-pressure side). Howev‐
er, because 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 no energy ex‐
change is taking place⇒ Vehicle diagnostic tester using “Gui‐
ded Fault Finding” function for air conditioner and battery
regulation control unit and ⇒ Heating, air conditioning; Rep.
gr. 00 ; Repair instructions; Checking the cooling output (ve‐
hicle-specific Workshop Manual).

256 Rep. gr.87 - Air conditioning system

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♦ The evaporator in the air conditioning unit is much more pow‐

erful than the evaporator for cooling the high-voltage compo‐
nents (e.g. in the battery cooling module or heat exchanger for
high-voltage battery). The shut-off valve (e.g. the refrigerant
shut-off valve 2 for hybrid battery - N517- on the expansion
valve in the battery cooling module or the refrigerant shut-off
valve to the heat exchanger for high-voltage battery - N542- )
is activated by the battery regulation control unit - J840- or air
conditioner operating and display unit, Climatronic control unit
- J255- when the battery reaches or exceeds a certain tem‐
perature, depending on the type of cooling used for the drive
battery - A2- / hybrid battery unit - AX1- (hybrid battery) so that
the energy exchanged 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 not no‐
tably increased ⇒ Vehicle diagnostic tester in “Guided Fault
Finding” mode for air conditioner and battery regulation and ⇒
Heating, air conditioning; Rep. gr. 00 ; Repair instructions;
Checking the cooling output .

Possible deviation from speci‐ Possible causes of fault Fault elimination

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- ) conditioner, air conditioner compres‐ • If the quantity of refrigerant
• High pressure normal sor and battery regulation . extracted is substantially
less than the specified ca‐
• low pressure too low (below ♦ Not enough refrigerant in circuit pacity:
specified value)
♦ Expansion valve for evaporator in air – Localise leak with leak de‐
• The required cooling output conditioning unit defective. tector and eliminate
is not attained solely at the
evaporator in the air condi‐ ♦ Shut-off valve upstream of the evapo‐ – Re-charge refrigerant circuit.
tioning unit (the cooling out‐ rator in the air conditioning unit (e.g. -
put is OK at the evaporator N516- or -N541- ) faulty (blocked)
– Repeat test.
for cooling the high-voltage
components). • If quantity of refrigerant ex‐
tracted roughly corresponds
to specified capacity:
– Check actuation and opera‐
tion of the shut-off valve (e.g.
-N516- or -N541- ). Renew
expansion valve at evapora‐
tor in air conditioning unit if
no fault is found.

– Re-charge refrigerant circuit.

– Repeat test.

8. Checking pressures 257

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Possible deviation from speci‐ Possible causes of fault Fault elimination

fication
• High pressure normal On vehicles with a battery cooling module – Check operation and actua‐
♦ 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 “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 the evaporator for – Check refrigerant lines
cooling the high-voltage components is
faulty. – Extract refrigerant from re‐
frigerant circuit.
♦ Not enough refrigerant in circuit
– Renew expansion valve with
On vehicles with a heat exchanger for -N517-
high-voltage battery
♦ Actuation or operation of the refrigerant – Check the restrictor in the re‐
shut-off valve to the heat exchanger for frigerant line to the heat ex‐
high-voltage battery - N542- , a faulty changer for high-voltage bat‐
refrigerant pump or a fault in the refrig‐ tery and clean or renew, if
erant circuit for the high-voltage com‐ necessary
ponents.
♦ Constriction or obstruction in the refrig‐ – Re-charge refrigerant circuit.
erant lines leading to or from the heat – Repeat test.
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

258 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

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

off valve 2 for hybrid battery - N517- is currently only actuated
by the battery regulation control unit - J840- in order to cool
the drive battery - A2- (hybrid battery) when the battery rea‐
ches a certain temperature. If air conditioning mode has not
already been activated at this point, the electrical air condi‐
tioner compressor - V470- is actuated via the control unit for
air conditioning compressor - J842- by -J840- . The tempera‐
ture 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 action is not sufficient, this is stor‐
ed in -J840- ⇒ Vehicle diagnostic tester, “Guided Fault Find‐
ing” function 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 256
♦ On vehicles with a heat exchanger for high-voltage battery, the
operating unit ( Climatronic control unit - J255- ) no longer ac‐
tivates the refrigerant shut-off valve to the heat exchanger for
high-voltage battery - N542- (the -N542- is de-energised and
open) after a certain temperature is exceeded in order to cool
the high-voltage components (e.g. the drive battery - A2- , the
high-voltage battery charger control unit - J1050- etc.). If air
conditioning mode has not already been activated at this point,
the operating unit -J255- actuates the electrical air conditioner
compressor - V470- via the control unit for air conditioning
compressor - J842- . Other components in this circuit must be
actuated (e.g. refrigerant circulation pump 2 - V178- and sol‐
enoid 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 cooling of the high-voltage components is not
sufficient, this is stored in various control units ⇒ Vehicle di‐
agnostic tester in “Guided Fault Finding” mode for air condi‐
tioner, air conditioner compressor and battery regulation and
⇒ Electric drive; Rep. gr. 93 ; Cooling system/refrigerant; In‐
stallation location - Cooling system .
♦ If no fault is found for this problem, clean refrigerant circuit (by
flushing with refrigerant R134a ⇒ page 116 or blowing out with
compressed air and nitrogen ⇒ page 108 ). Constriction or
blockage in the refrigerant circuit may also lead to one of these
problems.

8. Checking pressures 259

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Possible devia‐ Possible causes of Fault elimination

tion from specifi‐ fault
cation
On a vehicle with ♦ No actuation of – Check actuation
a shut-off valve air conditioner and operation of the
upstream of the compressor, air air conditioner com‐
evaporator in the conditioner com‐ pressor and repair if
air conditioning pressor is not necessary ⇒ Vehi‐
unit (e.g. -N516- driven. cle diagnostic test‐
or -N541- ) er, “Guided Fault
• High pres‐ ♦ Shut-off valve - Finding” function
sure does not N516- or -N541- for air conditioner
increase or defective and battery regula‐
only to slight‐ (blocked) tion
ly above the
pressure with – Check actuation
the engine and operation of -
stopped, N516- or -N541- .
Renew expansion
• low pressure valve at evaporator
does not de‐ in air conditioning
crease or on‐ unit if no fault is
ly slightly. found.
• The required
cooling out‐
put is not at‐
tained in the
evaporator in
the air condi‐
tioning unit
(and in the
evaporator
for cooling
the high-volt‐
age compo‐
nents).

♦ Constriction or – Clean refrigerant

blockage in the circuit (flush with re‐
refrigerant circuit frigerant R134a
(e.g. in the refrig‐ ⇒ page 116 or blow
erant pipe be‐ out with com‐
tween the “low- pressed air and ni‐
pressure end” trogen
service connec‐ ⇒ page 108 ).
tion and the air
conditioner com‐ – Renew hose or pipe
pressor). if kinked or constric‐
ted.
♦ The air condition‐ – Renew air condi‐
er compressor is tioner compressor.
defective.

260 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Possible deviation from spec‐ Possible causes of fault Fault elimination

ification
On a vehicle without a shut-off ♦ Actuation 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 obstruction in re‐ tic tester, “Guided Fault Finding”
• High pressure increases frigerant circuit function for air conditioner and bat‐
above specification ♦ Expansion valve defective tery regulation
• low pressure quickly drops – Run hand over refrigerant circuit to
to specified value, check for differences in temperature
• The required cooling out‐
put is not attained in the • If difference in temperature is found
evaporator in the air con‐ at one component:
ditioning unit (and in the – Renew hose or pipe if kinked or con‐
evaporator for cooling the stricted.
high-voltage compo‐
nents). – In the event of clogging, clean refrig‐
erant circuit (flush with refrigerant
R134a ⇒ page 116 or blow out with
compressed air and nitrogen
⇒ page 108 ).

– Re-charge refrigerant circuit.

– Repeat test.

• If operation is not OK and no fault is

found:
– Clean refrigerant circuit (flush with
refrigerant R134a ⇒ page 116 or
blow out with compressed air and ni‐
trogen ⇒ page 108 ).

– Re-charge refrigerant circuit.

– If function is not OK, repeat test:

– Renew expansion valve upstream of

evaporator in air conditioning unit
and receiver.
On a vehicle with a shut-off ♦ Actuation or operation of air con‐ – Check actuation of air conditioner
valve upstream of the evapo‐ ditioner compressor, -N516- or - compressor and -N516- ⇒ Vehicle
rator in the air conditioning N541- not OK. diagnostic tester in “Guided Fault
unit (e.g. -N516- or -N541- ) Finding” mode for air conditioner and
• High pressure increases ♦ Constriction or obstruction in re‐ battery regulation .
above specification frigerant circuit
– Further testing as described for ve‐
• low pressure quickly drops ♦ Expansion valve defective hicles without -N516- / -N541-
to specified value,
• The required cooling out‐
put is not attained in the
evaporator in the air con‐
ditioning unit (and in the
evaporator for cooling the
high-voltage compo‐
nents).

8. Checking pressures 261

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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).
♦ In this case, the evaporator may ice up although the correct
quantity of refrigerant is present in the refrigerant circuit.
♦ If the expansion valve at the evaporator in the air conditioning
unit or -N516- / -N541- is defective (is permanently closed or
does not open sufficiently), the air conditioner compressor is
actuated to maximum output and the low pressure drops to the
specified value or below (air conditioner compressor draws off
refrigerant from low-pressure side). However, as refrigerant
cannot flow (or insufficient refrigerant flows) via expansion
valve -N516- / -N541- , cooling output is not attained and high
pressure may also not increase or only increase slightly since
there is no energy exchange ⇒ Vehicle diagnostic tester in
“Guided Fault Finding” mode for air conditioner and battery
regulation and ⇒ Heating, air conditioning; Rep. gr. 00 ; Re‐
pair instructions; Checking the cooling output (vehicle-specific
Workshop Manual).
♦ 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 ( -
N516- is actuated and closed). The air conditioner compressor
draws off the refrigerant from the low-pressure side of both
evaporators. However, as no refrigerant can flow via the ex‐
pansion valve in the air conditioning unit ( -N516- ) and the
cooling output is not reached in the battery cooling module
(fault in area of battery cooling module), the electric air condi‐
tioner compressor is actuated at a higher speed. However, as
no more refrigerant can flow, the pressure on the low-pressure
side drops below the specified value, and high pressure may
also not increase or only increase slightly since there is no
energy exchange⇒ Vehicle diagnostic tester in “Guided Fault
Finding” mode for air conditioner and battery regulation and ⇒
Heating, air conditioning; Rep. gr. 00 ; Repair instructions;
Checking the cooling output (vehicle-specific Workshop Man‐
ual).

262 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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

the restrictor installed in the refrigerant line to the heat ex‐
changer for high-voltage battery is blocked or the refrigerant
shut-off valve to the heat exchanger for high-voltage battery -
N542- installed in this line is faulty, permanently closed or does
not open sufficiently, the air conditioner compressor is also
actuated to maximum output (the required temperatures in the
refrigerant circuit are not reached with the heat exchanger for
high-voltage battery). 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 actuated and closed). The air conditioner com‐
pressor draws off the refrigerant from the low-pressure end of
both evaporators). However, because refrigerant cannot flow
into the air conditioning unit (the -N541- ) via the expansion
valve and the cooling output in the heat exchanger for high-
voltage battery is not reached, 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 high pressure may
also not increase or only increase slightly since there is no
energy exchange⇒ Vehicle diagnostic tester in “Guided Fault
Finding” mode for air conditioner and battery regulation and ⇒
Heating, air conditioning; Rep. gr. 00 ; Repair instructions;
Checking the cooling output (vehicle-specific Workshop Man‐
ual). The same applies if a fault occurs in the refrigerant circuit
where the heat exchanger for high-voltage battery is installed
(e.g. Refrigerant circulation pump 2 - V178- or solenoid valve
1 - N88- are not activated correctly or are faulty). Although the
heat exchanger for high-voltage battery is cooled, the cooled
refrigerant does not reach the high-voltage components that
are supposed to be cooled ⇒ Heating, air conditioning; Rep.
gr. 87 ; Refrigerant circuit and ⇒ Electric drive; Rep. gr. 93 ;
Cooling system/refrigerant; Installation location - Cooling sys‐
tem .
♦ As the cooling output of the evaporator for cooling the high-
voltage battery is considerably 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 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 condi‐
tioner compressor is being activated at a higher speed).
♦ If there is too much refrigerant oil in the circuit, also drain
(flush) the air conditioner compressor and renew the receiver/
desiccant cartridge. After cleaning the refrigerant circuit (flush‐
ing with refrigerant R134a ⇒ page 116 or blowing out with
compressed air and nitrogen ⇒ page 108 ), add the correct
amount of refrigerant oil to the circuit (to the air conditioner
compressor) ⇒ page 332 .

8. Checking pressures 263

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Possible deviation from speci‐ Possible causes of fault Fault elimination

fication
• High and low pressure nor‐ ♦ Actuation or operation of air condition‐ – Check actuation of air condi‐
mal at first er compressor or -N516- / -N541- not tioner compressor and -
OK. N516- / -N541- ⇒ Vehicle
• After some time, high pres‐ diagnostic tester in “Guided
sure increases above spec‐ ♦ Moisture in refrigerant circuit Fault Finding” mode for air
ification and conditioner and battery reg‐
• Low pressure drops to ulation .
specified value or below,
– Clean refrigerant circuit
• The required cooling output (flush with refrigerant R134a
is not attained in the evap‐ ⇒ page 116 or blow out with
orator in the air conditioning compressed air and nitrogen
unit (and in the evaporator ⇒ page 108 ).
for cooling the high-voltage
components).

• 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 in – Re-charge refrigerant circuit.
the air conditioning unit ices
up). – Repeat test.

Note

♦ It is not initially necessary to clean the refrigerant circuit (flush

with refrigerant R134a ⇒ page 116 or blow out with com‐
pressed air and nitrogen ⇒ page 108 ) when this problem
occurs. Normally, there is only a small quantity of moisture in
the system which can be removed by lengthy evacuation.
♦ If a problem involving moisture in the refrigerant circuit only
occurs after a lengthy operating period or only infrequently
(low pressure drops below specification and evaporator ices
up), it is sufficient to renew the dryer in the receiver (adjust
quantity of refrigerant oil). Subsequently, evacuate refrigerant
circuit for at least 3 hours.
♦ In this case, the evaporator may ice up although the correct
quantity of refrigerant is present in the refrigerant circuit.
♦ A fault at the evaporator output temperature sender - G263-
or / and if fitted at the temperature sensor downstream of
evaporator for hybrid battery - G757- may also cause the re‐
frigerant circuit to ice up. If this problem occurs, also observe
the measured value for -G263- and -G757- (on vehicles with
a battery cooling module) ⇒ Vehicle diagnostic tester; in “Gui‐
ded Fault Finding” mode for air conditioner and ⇒ Heating, air
conditioning; Rep. gr. 00 ; Repair instructions; Checking the
cooling output (vehicle-specific Workshop Manual).

264 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Possible deviation from speci‐ Possible causes of fault Fault elimination

fication
• High pressure normal ♦ Actuation or operation of air condition‐ – Check actuation and opera‐
er compressor or -N516- , -N517- , - tion of air conditioner com‐
• Low pressure too low N541- or -N542- (if installed) not OK. pressor and -N516- / -N517-
• The required cooling output (if installed) ⇒ Vehicle
♦ Expansion valve in air conditioning unit diagnostic tester in “Guided
is not attained in the evap‐ or, if fitted, in battery cooling module
orator in the air conditioning Fault Finding” mode for air
defective. conditioner and battery reg‐
unit (and in the evaporator
for cooling the high-voltage ♦ Expansion valve in the air conditioning ulation .
components). 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
⇒ page 116 or blow out with
♦ The air conditioner compressor is de‐ compressed air and nitrogen
fective. ⇒ page 108 ) (not always
necessary, refer to notes).

– Renew expansion valve for

the evaporator in the air con‐
ditioning unit and for the re‐
ceiver / oven.

– If available, renew the ex‐

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

– Re-charge refrigerant circuit.

– If function is not OK, repeat

test:

– Renew air conditioner com‐

pressor.

– Re-charge refrigerant circuit.

– Repeat test.

8. Checking pressures 265

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

♦ Observe the following regarding fault “High pressure normal,

low pressure too low”: This fault may cause the evaporator in
the air conditioning unit to ice up although the amount of re‐
frigerant 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 116 or blowing out with com‐
pressed air and nitrogen ⇒ page 108 ). In this case it is
sufficient to renew the air conditioner compressor (observe
quantity of refrigerant oil in compressor and adjust if neces‐
sary).
♦ 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. The air con‐
ditioner compressor may however be actuated at higher
speed, as the required cooling output is not being attained in
one evaporator. The same also applies if operation or actua‐
tion of the shut-off valve 1 for refrigerant of hybrid battery -
N516- or shut-off valve 2 for refrigerant of hybrid battery -
N517- is not OK ⇒ Vehicle diagnostic tester; Function “Guided
Fault Finding” for air conditioner and ⇒ Heating, air condition‐
ing; Rep. gr. 00 ; Repair instructions; Checking the cooling
output (vehicle-specific Workshop Manual).
♦ On vehicles with a heat exchanger for high-voltage battery, if
the expansion valve for the evaporator in the air conditioning
unit is defective (permanently closed or does not open suffi‐
ciently) or the restrictor in the refrigerant line to the heat
exchanger for high-voltage battery is blocked, the air condi‐
tioner 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 re‐
frigerant from the low-pressure side). As refrigerant cannot
however flow via the defective expansion valve or blocked re‐
strictor, 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 conver‐
sion. The air conditioner compressor may however be actu‐
ated at higher speed, as the required cooling output is not
being attained in one evaporator. The same also applies if op‐
eration or actuation of the shut-off valve for refrigerant to the
heater and air conditioning unit - N541- , shut-off valve for re‐
frigerant to the heat exchanger for high-voltage battery - N542-
or a component installed in the refrigerant circuit for the high-
voltage components (e.g. refrigerant circulation pump 2 -
V178- or solenoid valve 1 - N88- is not OK ⇒ Vehicle diagnostic
tester; in “Guided Fault Finding” mode of the air conditioning
unit, ⇒ Electric drive; Rep. gr. 93 ; Cooling system/refrigerant;
Installation location - Cooling system and ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific Workshop Manual).

266 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

♦ Check the measured values for the evaporator output tem‐

perature sender - G263- (and if applicable the measured
values for the temperature sensor upstream of evaporator for
hybrid battery - G756- and the temperature sensor down‐
stream of evaporator for hybrid battery - G757- ) as well as
actuation of the air conditioner compressor by the battery reg‐
ulation control unit - J840- or the operating unit for air condi‐
tioning unit, the Climatronic control unit - J255- . If the
measured value of -G263- (or -G756- , -G757- ) or actuation
of the air conditioner compressor is not OK, the evaporator
may ice up or the required cooling output is not attained ⇒ Ve‐
hicle diagnostic tester; Function “Guided Fault Finding” for air
conditioner and ⇒ Heating, air conditioning; Rep. gr. 00 ; Re‐
pair instructions; Checking the cooling output (vehicle-specific
Workshop Manual).

Possible deviation from speci‐ Possible causes of fault Fault elimination

fication
• High pressure normal or too ♦ Actuation or operation of air condition‐ – Check actuation and opera‐
high er compressor not OK. tion of air conditioner com‐
pressor and -N516- , -N517- ,
• low pressure too high, ♦ Actuation or operation of one of these -N541- and -N542- (if instal‐
shut-off valves -N516- , -N517- , - led) ⇒ Vehicle diagnostic
• Air conditioner compressor N541- or -N542- is not OK, irrespective
noise (particularly after tester in “Guided Fault Find‐
of the refrigerant circuit version ing” mode for air conditioner
switch-on),
♦ Too much refrigerant in the circuit. and battery regulation .
• The required cooling output
is not attained in the evap‐ ♦ Expansion valve defective – Extract refrigerant from re‐
orator in the air conditioning frigerant circuit.
unit and / or in the evapora‐ ♦ The air conditioner compressor is de‐
tor for cooling the high-volt‐ fective. • The quantity of refrigerant
age components. extracted roughly corre‐
sponds to the actual capaci‐
ty.
– Renew expansion valve for
the evaporator in the air con‐
ditioning unit and for the re‐
ceiver / oven.
– Renew expansion valve with
-N517-

– Check the restrictor in the re‐

frigerant line to the heat ex‐
changer for high-voltage bat‐
tery and clean or renew, if
necessary

– Re-charge refrigerant circuit.

– Repeat the test, if operation

is not OK:

– Renew the air conditioning

system compressor.

• If quantity of refrigerant ex‐

tracted is substantially great‐
er than specified capacity:
– Re-charge refrigerant circuit.

– Repeat test.

8. Checking pressures 267

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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.
♦ 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. The air con‐
ditioner compressor may however be actuated at higher
speed, as the required cooling output is not being attained in
one evaporator. The same also applies if operation or actua‐
tion of the shut-off valve 1 for refrigerant of hybrid battery -
N516- or shut-off valve 2 for refrigerant of hybrid battery -
N517- is not OK ⇒ Vehicle diagnostic tester; “Guided Fault
Finding” mode for air conditioner and ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific Workshop Manual).
♦ On vehicles with a heat exchanger for high-voltage battery, if
the expansion valve for the evaporator in the air conditioning
unit is defective (permanently closed or does not open suffi‐
ciently) or the restrictor in the refrigerant line to the heat
exchanger for high-voltage battery is blocked, the air condi‐
tioner 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 re‐
frigerant from the low-pressure side). As refrigerant cannot
however flow via the defective expansion valve or blocked re‐
strictor, 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 conver‐
sion. The air conditioner compressor may however be actu‐
ated at higher speed, as the required cooling output is not
being attained in one evaporator. The same also applies if op‐
eration or actuation of the shut-off valve for refrigerant to the
heater and air conditioning unit - N541- , shut-off valve for re‐
frigerant to the heat exchanger for high-voltage battery - N542-
or a component installed in the refrigerant circuit for the high-
voltage components (e.g. refrigerant circulation pump 2 -
V178- or solenoid valve 1 - N88- is not OK ⇒ Vehicle diagnostic
tester; in “Guided Fault Finding” mode of the air conditioning
unit, ⇒ Electric drive; Rep. gr. 93 ; Cooling system/refrigerant;
Installation location - Cooling system and ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific Workshop Manual).

268 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Possible deviation from speci‐ Possible causes of fault Fault elimination

fication
• High and low pressure nor‐ ♦ Actuation or operation of air condition‐ – Check actuation and opera‐
mal er compressor not OK. tion of air conditioner com‐
pressor and -N516- , -N517- ,
• The required cooling output ♦ Actuation or operation of one of these -N541- and -N542- (if instal‐
is not attained in the evap‐ shut-off valves -N516- , -N517- , - led) ⇒ Vehicle diagnostic
orator in the air conditioning N541- or -N542- is not OK, irrespective tester in “Guided Fault Find‐
unit (and in the evaporator of the refrigerant circuit version ing” mode for air conditioner
for cooling the high-voltage and battery regulation .
components). ♦ Too much refrigerant in the circuit.
♦ Expansion valve defective – Discharge refrigerant circuit.

– Clean refrigerant circuit

(flush with refrigerant R134a
⇒ page 116 or blow out with
compressed air and nitrogen
⇒ page 108 ).
• High and low pressure nor‐ – Add the correct quantity of
mal refrigerant oil to the circuit
(refer to note).
• Air conditioner compressor
noise (particularly after – Re-charge refrigerant circuit.
switch-on),
• The required cooling output – If function is not OK, repeat
is not attained in the evap‐ test:
orator in the air conditioning
unit (and / or in the evapo‐ – Renew expansion valve.
rator for cooling the high-
voltage components). – Re-charge refrigerant circuit.

– Repeat test.

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 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
cause noise (liquid cannot be compressed).
♦ If there is too much refrigerant oil in the circuit, drain the air
conditioner compressor and renew the receiver. After cleaning
the refrigerant circuit (flushing with refrigerant R134a
⇒ page 116 ), add the correct amount of refrigerant oil to the
circuit ⇒ page 332 .

8. Checking pressures 269

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9 Renewing components of refrigerant

circuit
⇒ “9.1 Renewing components”, page 270

9.1 Renewing components

WARNING

Safety hazard: the engine can start unexpectedly.

Before carrying out general work on a vehicle with high-voltage
electrical system, switch off the ignition and remove the ignition
key from the vehicle.

WARNING

Working on vehicles with high-voltage wiring:

270 Rep. gr.87 - Air conditioning system

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DANGER!

Risk of fatal injury if high-voltage components are damaged.

If work is necessary in the vicinity of high-voltage system com‐

9. Renewing components of refrigerant circuit 271

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DANGER!

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock.
♦ The high-voltage system may only be de-energised by a
suitably qualified person (Audi high-voltage technician).
♦ It must be definitely confirmed that the high-voltage sys‐
tem is de-energised. The system may only be de-ener‐
gised using the vehicle diagnostic tester via “Guided Fault
Finding”.
♦ The qualified person (Audi high-voltage technician) en‐
sures that the system is de-energised and secured with
the locking cap - T40262- to prevent anyone from switch‐
ing it on. Furthermore, the qualified person must also store
the ignition key and maintenance connector for high-volt‐
age system - TW - in a safe place as an additional meas‐
ure to prevent the system from being switched back on.
♦ The qualified person (Audi high-voltage technician) marks
the vehicle by attaching the appropriate warning signs.

Note

♦ De-energising high-voltage system:

Re-energising high-voltage system

272 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
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DANGER!

High voltage can cause fatal injury.

Note

♦ Re-energising high-voltage system:

DANGER!

When working on a vehicle with the ignition switched on or

– 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

9. Renewing components of refrigerant circuit 273

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charger 60A - VAS 5904- in battery standby mode ⇒ Electrical

Note

Vehicles with start/stop system

WARNING

Injury risk due to automatic engine start (vehicles with start/

All vehicles

WARNING

Risk of injury (frostbite).

• All components of the refrigerant circuit that are to submitted

to quality monitoring must always be sealed (use the original
sealing caps from the replacement part).
• The replacement air conditioner compressor, reservoir, re‐
ceiver, evaporator and condenser are charged with nitrogen
before shipment. This charge is being gradually discontinued/
the pressure of the nitrogen charge is now so low that the es‐
cape of gas is no longer perceptible on initial opening.
• On vehicles fitted with an air conditioner compressor with no
magnetic clutch, the engine is only to be started following

274 Rep. gr.87 - Air conditioning system

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complete assembly of the refrigerant circuit (constant air con‐

ditioner compressor 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 replacement parts are sometimes stored for lengthy peri‐

ods and at different locations, it is quite possible that gas will
escape from some parts and not from others on initial opening
(even in the case of identical replacement part numbers). The
sealing caps at the replacement part connections are there‐
fore to be detached carefully and the nitrogen gas allowed to
escape slowly.
♦ Refrigerant circuits are fitted either with a restrictor and reser‐
voir or with an expansion valve and receiver.
♦ The desiccant cartridge or components with desiccant bag
(reservoir, receiver) are always to be renewed after cleaning
the refrigerant circuit (flushing with refrigerant R134a
⇒ page 116 or blowing out with compressed air and nitrogen
⇒ page 108 ); in doing so, leave sealed as long as possible to
minimise the absorption of moisture.
♦ Renew the desiccant cartridge or components with desiccant
bag (reservoir, receiver) if required for certain repair opera‐
tions or if the refrigerant circuit has been open for a lengthy
period and moisture has ingressed (e.g. following an accident)
⇒ page 276 .
♦ The period of time for which a refrigerant circuit may be left
open without having to renew a component with desiccant bag
(reservoir, receiver) is largely governed by ambient influences.
Given a high ambient temperature and a high humidity level
or if the vehicle has been standing in the open for example or
driven (in wet, foggy weather conditions), the period will be
considerably shorter than for a vehicle which has been stand‐
ing in a heated dry area. The size of the opening through which
moisture may ingress 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 276 .
♦ Seal open connections and lines (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 275

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⇒ “9.1.1 Leaking or damaged components (except air conditioner

compressor, reservoir or receiver)”, page 276
⇒ “9.1.2 Leaking or damaged components (except air conditioner
compressor, reservoir or receiver)”, page 278
⇒ “9.1.3 Renewing air conditioner compressor without the need
for refrigerant circuit cleaning”, page 278
⇒ “9.1.4 Renewing air conditioner compressor on account of leak‐
age or internal damage”, page 281
⇒ “9.1.5 Renewing receiver or reservoir and restrictor after clean‐
ing refrigerant circuit”, page 286
⇒ “9.1.6 Renewing receiver or reservoir without the need for re‐
frigerant circuit cleaning”, page 287
⇒ “9.1.7 Renewing desiccant cartridge/desiccant bag without the
need for refrigerant circuit cleaning”, page 288
⇒ “9.1.8 Removing/installing and renewing air conditioner com‐
pressor regulating valve N280 ”, page 289

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 operations marked * are only to be implemented in the
case of a major leak (e.g. following an accident).

Electrically driven air conditioner compressor

– Removing faulty component ⇒ Heating, air conditioning; Rep.
gr. 87 ; Refrigerant circuit; System overview - Refrigerant cir‐
cuit (vehicle-specific Workshop Manual).
– Remove and flush the electrically driven air conditioner com‐
pressor ⇒ page 134 *.
– Clean the refrigerant circuit (flush with refrigerant R134a)
⇒ page 116 *.
– Pour the full specified quantity of refrigerant oil into the air
conditioner compressor or circuit *.
Mechanically driven air conditioner compressor
– Removing faulty component ⇒ Heating, air conditioning; Rep.
gr. 87 ; Refrigerant circuit; System overview - Refrigerant cir‐
cuit (vehicle-specific Workshop Manual).
– Removing the air conditioner compressor ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Air conditioner compressor (vehicle-
specific Workshop Manual)*.

276 Rep. gr.87 - Air conditioning system

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Air conditioner with refrigerant R134a - Edition 11.2014

– Remove the oil drain plug -B- / -D- from the 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).
♦ Pay attention to the 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) ⇒ Heating,
air conditioning; Rep. gr. 87 ; Air conditioner compressor (ve‐
hicle-specific Workshop Manual).
♦ On the “Denso” or “Nippondenso” air conditioner compressor,
the oil drain plug -D- is fitted with a sealing ring -E- for example;
renewing ⇒ Electronic parts catalogue .
♦ On the “Sanden” or “Zexel” air conditioner compressor, the oil
drain plug -B- is fitted with an O-ring -C- for example; renewing
⇒ Electronic parts catalogue .
♦ To accelerate drainage of the refrigerant oil, crank the air con‐
ditioner compressor by way of the magnetic clutch plate for
example.
♦ Pour the old refrigerant oil out of the air conditioner compres‐
sor (disposal ⇒ Audi ServiceNet, HSO Environmental Protec‐
tion ).

All models

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 332 *.
♦ Use different refrigerant oils and quantities for the various air
conditioner compressors ⇒ page 332 .
♦ 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 332 .
♦ If dirt has ingressed 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 116 or blow out with compressed air or nitrogen
⇒ page 108 )*.

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

strictor ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit; System overview - refrigerant circuit (vehicle-specific
Workshop Manual).
– Assemble, evacuate and re-charge refrigerant circuit.

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9.1.2 Leaking or damaged components (ex‐

cept air conditioner compressor, reser‐
voir or receiver)
Refrigerant circuit still contains refrigerant (e.g. minor leak)
– Discharge refrigerant circuit.
– Remove the defective component, blow out with compressed
air and collect the refrigerant oil escaping.
– Fill the new component with the amount of refrigerant oil blown
out (plus 20 cm3 for the evaporator, plus 10 cm3 for the con‐
denser, refrigerant pipes and refrigerant hoses) as fresh re‐
frigerant oil fill.

Note

Disposal of old refrigerant oil ⇒ Audi-ServiceNet, HSO Environ‐

mental Protection .

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

Refrigerant circuit; System overview - refrigerant circuit (vehi‐
cle-specific Workshop Manual).
– Assemble, evacuate and charge refrigerant circuit.

9.1.3 Renewing air conditioner compressor

without the need for refrigerant circuit
cleaning

Note

♦ Cleaning the refrigerant circuit means flushing with refrigerant

R134a ⇒ page 116 .
♦ 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 333 .

For example in the event of exterior damage after an accident (or

in the event of an electrical fault)
– Discharge refrigerant circuit.
– Removing the air conditioner compressor ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Air conditioner compressor (vehicle-
specific Workshop Manual).

Note

Use different refrigerant oils and quantities for the various air con‐
ditioner compressors
⇒ “10.2.2 Refrigerant oil capacities”, page 335 .

Electrically driven air conditioner compressor

♦ 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‐

278 Rep. gr.87 - Air conditioning system

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Air conditioner with refrigerant R134a - Edition 11.2014

sor (removing refrigerant oil)”, page 134 ) 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 335 ).
Example:
♦ 120 cm3 was flushed out of the air conditioner compressor to
be renewed
⇒ “5.5.2 Flushing electrically driven air conditioner compressor
(removing refrigerant oil)”, page 134 .
♦ The air conditioner compressor to be installed contains 200
cm3 of refrigerant oil (see rating plate and
⇒ “10.2.2 Refrigerant oil capacities”, page 335 ).
– Pour refrigerant oil out of the new air conditioner compressor
(first using the connection for the refrigerant pipe 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).

9. Renewing components of refrigerant circuit 279

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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
⇒ “5.5.2 Flushing electrically driven air conditioner compressor
(removing refrigerant oil)”, page 134 .
♦ 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
⇒ “5.5.2 Flushing electrically driven air conditioner compressor
(removing refrigerant oil)”, page 134 .
♦ 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).

Mechanically driven air conditioner compressor

– 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 sealing ring may be fitted, always
renew) ⇒ page 276 and ⇒ Electronic parts catalogue .

280 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

– To accelerate drainage of the refrigerant oil, crank the air con‐

ditioner compressor by way of the magnetic clutch plate for
example.
– 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).
♦ Use different refrigerant oils and quantities for the various air
conditioner compressors ⇒ page 294 .
♦ 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 294 .

All models
– Renew restrictor (only if installed in this refrigerant circuit).
– Assemble, evacuate and charge refrigerant circuit.

9.1.4 Renewing air conditioner compressor

on account of leakage or internal dam‐
age
Vehicles with high-voltage system (hybrid vehicles)
For all work on vehicles with a high-voltage system, note the ad‐
ditional warning instructions for working on such vehicles
⇒ “1 Warning instructions when working on vehicles with high-
voltage system”, page 1 and ⇒ Electrical system; Rep. gr. 93 ;
General warning instructions for work on the high-voltage sys‐
tem .

9. Renewing components of refrigerant circuit 281

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
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WARNING

Safety hazard: the engine can start unexpectedly.

Before carrying out general work on a vehicle with high-voltage
electrical system, switch off the ignition and remove the ignition
key from the vehicle.

WARNING

Working on vehicles with high-voltage wiring:

DANGER!

Risk of fatal injury if high-voltage components are damaged.

282 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
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If work is necessary in the vicinity of high-voltage system com‐

DANGER!

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock.
♦ The high-voltage system may only be de-energised by a
suitably qualified person (Audi high-voltage technician).
♦ It must be definitely confirmed that the high-voltage sys‐
tem is de-energised. The system may only be de-ener‐
gised using the vehicle diagnostic tester via “Guided Fault
Finding”.
♦ The qualified person (Audi high-voltage technician) en‐
sures that the system is de-energised and secured with
the locking cap - T40262- to prevent anyone from switch‐
ing it on. Furthermore, the qualified person must also store
the ignition key and maintenance connector for high-volt‐
age system - TW - in a safe place as an additional meas‐
ure to prevent the system from being switched back on.
♦ The qualified person (Audi high-voltage technician) marks
the vehicle by attaching the appropriate warning signs.

Note

♦ De-energising high-voltage system:

Re-energising high-voltage system

9. Renewing components of refrigerant circuit 283

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
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DANGER!

High voltage can cause fatal injury.

Note

♦ Re-energising high-voltage system:

DANGER!

When working on a vehicle with the ignition switched on or

– 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

284 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

charger 60A - VAS 5904- in battery standby mode ⇒ Electrical

Note

All vehicles
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. It is usually sufficient here to renew the air conditioner
compressor without cleaning the refrigerant circuit (adjust the
quantity of refrigerant oil)
⇒ “9.1.3 Renewing air conditioner compressor without the
need for refrigerant circuit cleaning”, page 278 .
♦ 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 333 .

– Discharge refrigerant circuit.

– Removing the air conditioner compressor ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Air conditioner compressor (vehicle-
specific Workshop Manual).
– Clean the refrigerant circuit (flush with refrigerant R134a)
⇒ page 116 .

9. Renewing components of refrigerant circuit 285

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Note

♦ In the event of internal (air conditioner compressor) damage,

check the refrigerant hoses and condenser. If, e.g. swarf has
ingressed, clean the refrigerant hoses and condenser (flush
with refrigerant R134a ⇒ page 116 ) and renew the 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 108 .

– Renew desiccant cartridge, receiver or reservoir and restrictor

⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - refrigerant circuit (vehicle-specific Work‐
shop Manual).
– Check expansion valve for dirt or corrosion, renew if neces‐
sary ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit; System overview - refrigerant circuit (vehicle-specific
Workshop Manual).
– Assemble, evacuate and charge refrigerant circuit.

9.1.5 Renewing receiver or reservoir and re‐

strictor after cleaning refrigerant circuit

Note

Cleaning the refrigerant circuit means flushing with refrigerant

R134a ⇒ page 116 or blowing out with compressed air or nitrogen
⇒ page 108 .

For example on account of ingress of moisture (refrigerant circuit

open for lengthy period) or contamination
– Discharge refrigerant circuit.
– Removing the air conditioner compressor ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Air conditioner compressor (vehicle-
specific Workshop Manual).
– Eliminate cause of fault.
– Clean refrigerant circuit (flush with refrigerant R134a)
⇒ page 116 .
– Check expansion valve for dirt or corrosion and renew if nec‐
essary
Electrically driven air conditioner compressor
– Flush the old refrigerant oil out of the air conditioner compres‐
sor
⇒ “5.5.2 Flushing electrically driven air conditioner compressor
(removing refrigerant oil)”, page 134 .
Mechanically driven air conditioner compressor
– Remove oil drain screw from air conditioner compressor.

286 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
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Note

There are different versions of the oil drain plug and the corre‐
sponding seal (an O-ring or a sealing ring may be fitted, renew)
⇒ page 276 and ⇒ Electronic parts catalogue .

– To accelerate drainage of the refrigerant oil, crank the air con‐

ditioner compressor by way of the magnetic clutch plate for
example.
– Pour the old refrigerant oil out of the air conditioner compres‐
sor.

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 332 .

Note

♦ Use different refrigerant oils and quantities for the various air
conditioner compressors ⇒ page 332 .
♦ 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 294 .
♦ If dirt enters the air conditioner compressor whilst the refrig‐
erant circuit is open (e.g. after an accident), the air conditioner
compressor should be renewed.
♦ 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 108 .

All vehicles
– Renew receiver or reservoir and restrictor ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
refrigerant circuit (vehicle-specific Workshop Manual).
– Assemble, evacuate and charge refrigerant circuit.

9.1.6 Renewing receiver or reservoir without

the need for refrigerant circuit cleaning

Note

Cleaning refrigerant circuit means flushing with refrigerant R134a

⇒ page 116 or blowing out with compressed air or nitrogen
⇒ page 108 .

9. Renewing components of refrigerant circuit 287

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Air conditioner with refrigerant R134a - Edition 11.2014

For example in the event of accident damage; no refrigerant es‐

caped and no ingress of moisture and dirt into the circuit.
– Discharge refrigerant circuit.
– Renew restrictor ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit; System overview - refrigerant circuit (vehi‐
cle-specific Workshop Manual).
– Remove receiver or reservoir⇒ Heating, air conditioning; Rep.
gr. 87 ; Refrigerant circuit; System overview - Refrigerant cir‐
cuit (vehicle-specific Workshop 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.
– Assemble, evacuate and charge refrigerant circuit.

9.1.7 Renewing desiccant cartridge/desiccant

bag without the need for refrigerant cir‐
cuit cleaning

Note

Cleaning the refrigerant circuit means flushing with refrigerant

R134a ⇒ page 116 or blowing out with compressed air or nitrogen
⇒ page 108 .

For example in the event of a leak; refrigerant has escaped but

no dirt has ingressed into the circuit.
– Discharge refrigerant circuit.
– Renew desiccant cartridge ⇒ Heating, air conditioning; Rep.
gr. 87 ; Refrigerant circuit; System overview - refrigerant cir‐
cuit (vehicle-specific Workshop Manual).
– Assemble, evacuate and charge refrigerant circuit.

288 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

9.1.8 Removing/installing and renewing air

conditioner compressor regulating valve
- N280-

Note

♦ Certain -N280- malfunctions (e.g. valve sticking or open circuit

in coil) can lead to problems with the air conditioner compres‐
sor (no air conditioner cooling action, icing-up of evaporator
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 replacement part for all air
conditioner compressors. If -N280- cannot be obtained as a
separate air conditioner compressor component, the entire air
conditioner compressor must be replaced ⇒ Electronic parts
catalogue .
♦ There are different versions of -N280- with different assign‐
ments ⇒ Electronic parts catalogue . On the air conditioner
compressor -A- (in this case a “Denso” air conditioner com‐
pressor), 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-.
Removal and installation of -N280- -C, D - for other air condi‐
tioner compressors (different type, different make) are essen‐
tially the same and usually only differ slightly from the
procedure described below.
♦ 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 replace
the air conditioner compressor
⇒ “9.1.4 Renewing air conditioner compressor on account of
leakage or internal damage”, page 281 and
⇒ “5.5 Cleaning (flushing) refrigerant circuit with refrigerant
R134a”, page 116

Removing
– Drain the refrigerant circuit
⇒ “5.3 Working with the air conditioner service station”,
page 90 .

Caution

Risk of air conditioner compressor damage if the refrigerant

9. Renewing components of refrigerant circuit 289

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– Depending on the vehicle and the installation location of the

air conditioner compressor, remove the components impeding
access to -N280- ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit; System overview - Refrigerant circuit (ve‐
hicle-specific Workshop Manual).
On vehicles on which 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.
– Removing the air conditioner compressor ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Air conditioner compressor (vehicle-
specific 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.

On vehicles on which it is possible to detach or remove at least

one of the two refrigerant lines and -N280- with the air conditioner
compressor attached to the engine (air conditioner compressor is
not removed)

WARNING

Risk of injury (frostbite).

♦ 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 the air conditioner
compressor ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
erant circuit; System overview - Refrigerant circuit (vehicle-
specific 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.

290 Rep. gr.87 - Air conditioning system

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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”. With 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 mount for -N280- -C- as far as the O-ring -F-.

– If fitted, unfasten the wiring from -N280- -B- to the vehicle wir‐
ing harness connector from the air conditioner compressor.

Note

In the case of an air conditioner compressor with air conditioning

system magnetic clutch - N25- , on which -N25- is actuated by
way of the same connector as -N280- -B-, eject the corresponding
wires from the connector ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit; System overview - Refrigerant circuit (ve‐
hicle-specific Workshop Manual).

– 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 refrigeration 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 the circlip -A-.

– Carefully remove -N280- -B- from the mount of the air condi‐
tioner compressor -C- using a suitable screwdriver -D- for
example.

9. Renewing components of refrigerant circuit 291

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– After removal, check -N280- -B- and the mount in the air con‐
ditioner compressor -C- for contamination.

Note

♦ If the strainer -D-, -N280- -B- as far as the O-ring -F- or the
mount in the air conditioner compressor -C- is severely con‐
taminated in this area (e g. with swarf or dark, tacky abrasion),
this is an indication of air conditioner compressor damage. In
this case, clean the refrigerant circuit and replace the air con‐
ditioner compressor
⇒ “9.1.4 Renewing air conditioner compressor on account of
leakage or internal damage”, page 281 and
⇒ “5.5 Cleaning (flushing) refrigerant circuit with refrigerant
R134a”, page 116
♦ If the strainer -D- at -N280- -B- and the mount in the air con‐
ditioner 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-.
♦ In the case of an -N280- -B- with no O-ring -E-, dirt may have
ingressed into the mount -C- as far as the O-ring -E- during
operation. Carefully and completely remove this dirt using a
lint-free cloth for example (do not use compressed air).

Installing
– Check the mount of 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 mount could lead to renewed failure of -N280-
-B- or the air conditioner compressor
♦ If necessary, carefully clean the mount of the air condi‐
tioner compressor -C- with a fresh lint-free cloth (do not
use compressed air).
♦ When cleaning the mount -C-, make sure no dirt ingresses
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 mount are damaged.

– Check the mount of the air conditioner compressor -C- for

damage (also watch out for slight scratches in the surface; re‐
place the air conditioner 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 refrigeration oil and check for proper at‐
tachment.
– Insert -N280- -B- as far as it will go in the mount of the air
conditioner compressor -C-.
– Fit a new circlip -A- and check for correct positioning in the
groove.
– Re-install all parts removed in reverse order.

292 Rep. gr.87 - Air conditioning system

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– Evacuate and re-charge the refrigerant circuit

⇒ “5.3 Working with the air conditioner service station”,
page 90 .

Note

If refrigeration oil has emerged with -N280- -B- removed, use the
air conditioner service station to add this quantity of refrigeration
oil when charging the refrigerant circuit
⇒ “5.3 Working with the air conditioner service station”,
page 90 .

– Check operation of the air conditioner

⇒ “8 Checking pressures”, page 206 and ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific Workshop Manual).

9. Renewing components of refrigerant circuit 293

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Air conditioner with refrigerant R134a - Edition 11.2014

10 Capacities for refrigerant R134a/re‐

frigerant oil and approved refrigerant
oils
⇒ “10.1 Capacities for refrigerant R134a”, page 294
⇒ “10.2 Approved refrigerant oils and refrigerant oil capacities”,
page 332

10.1 Capacities for refrigerant R134a

Note

♦ When charging refrigerant circuits on the high-pressure side,

always fill as far as the upper tolerance limit (liquid refrigerant
remains in the charging hoses).
♦ Unless otherwise stated, the capacities specified for refriger‐
ant R134a also apply to the corresponding “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 filling accuracy of the air conditioner
service station may vary.
♦ For air conditioner compressor assignment (“Zexel / Valeo”,
“Sanden” or “Denso / Nippondenso”), refer to the ⇒ Electronic
parts catalogue and ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit; System overview - Refrigerant circuit (ve‐
hicle-specific Workshop Manual).
♦ Fill refrigerant circuits converted from R12 to R134a with the
quantity indicated in the Workshop Manual “Air conditioner
with refrigerant R12”. ⇒ Air conditioner with refrigerant R12
(this Workshop Manual is only available in hardcopy form).
♦ 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).

♦ ⇒ “10.1.1 Capacities for Audi A1 (8X_) 2011 ►”, page 295

♦ ⇒ “10.1.2 Capacities for Audi A2 (8Z_) 2001 ►”, page 296
♦ ⇒ “10.1.3 Capacities for Audi A3 (8L_) 1997 ► and Audi TT
(8N_) 1999 ►”, page 297
♦ ⇒ “10.1.4 Capacities for Audi A3 (8P_) 2004 ►, Audi Q3 (8U_
or 84_ for China) 2012 ►”, page 299
♦ ⇒ “10.1.5 Capacities for Audi A3 (8V_ or 85_ for China) 2013
►, Audi A3 e-tron (8V_ ) 2015 ►”, page 300
♦ ⇒ “10.1.6 Capacities for Audi TT (8J_) 2007 ►”, page 301
♦ ⇒ “10.1.7 Capacities for Audi TT (FV_) 2015 ►”, page 302
♦ ⇒ “10.1.8 Capacities for Audi 80 (8A_ / 8C_), Audi Coupé
(8B_), Audi Cabriolet (8G_) ► 2002”, page 302
♦ ⇒ “10.1.9 Capacities for Audi A4 (8D_) 1995 ► ”, page 303
♦ ⇒ “10.1.10 Capacities for Audi A4 (8E_) 2001 ►, Audi A4 Cab‐
riolet (8H_) 2003 ►”, page 305

294 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

♦ ⇒ “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 307
♦ ⇒ “10.1.12 Capacities for Audi 100 / Audi A6 (4A_) ► 1998”,
page 317
♦ ⇒ “10.1.13 Capacities for Audi A6 (4B_) 1998 ► and Audi all‐
road (4B_) ► 2005”, page 318
♦ ⇒ “10.1.14 Capacities for Audi A6 (4F_) 2005 ►”, page 323
♦ ⇒ “10.1.15 Capacities for Audi A6 (4G_ or 4X_ for China ) 2011
►, Audi A7 (4G_ or 4X_ for China) 2011 ►, Audi A6 Hybrid
(4G_) 2012 ►”, page 324
♦ ⇒ “10.1.16 Capacities for Audi V8 (4C_) ► 1994”, page 325
♦ ⇒ “10.1.17 Capacities for Audi A8 (4D_) 1994 ►”, page 326
♦ ⇒ “10.1.18 Capacities for Audi A8 (4E_) 2003 ►”, page 327
♦ ⇒ “10.1.19 Capacities for Audi A8 (4H_) 2010 ►, Audi A8 hybrid
(4H_) 2012 ►”, page 328
♦ ⇒ “10.1.20 Capacities for Audi Q7 (4L_) 2006 ►”, page 330
♦ ⇒ “10.1.21 Capacities for Audi R8 (42_) 2008 ►”, page 331

10.1.1 Capacities for Audi A1 (8X_) 2011 ►

Characteristics of refrigerant circuit:
• Expansion valve
• Receiver
• “Denso”, “Sanden” (or “Delphi”) air conditioner compressor
with air conditioner compressor regulating valve - N280- ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - Refrigerant circuit (vehicle-specific Work‐
shop Manual) and ⇒ Electronic parts catalogue
Vehicle model Production period Capacity in grammes Differing characteristics of this refrigerant
circuit
Audi A1 From 08.10 on‐ 500 + / - 15 • None
wards

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 295
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Air conditioner with refrigerant R134a - Edition 11.2014

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
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant cir‐
cuit; System overview - Refrigerant circuit (vehicle-specific
Workshop Manual).
♦ 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‐
tioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific Workshop 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 336 .
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.

10.1.2 Capacities for Audi A2 (8Z_) 2001 ►

Characteristics of refrigerant circuit:
• 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 grammes 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”.

296 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 bore diameter must always be used.
♦ A restrictor with a smaller bore (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
conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - Refrigerant circuit (vehicle-specific Workshop Manual)
and ⇒ Electronic parts catalogue .

10.1.3 Capacities for Audi A3 (8L_) 1997 ► and

Audi TT (8N_) 1999 ►
Characteristics of refrigerant circuit:
• Expansion valve
• Receiver
• “Sanden” or “Zexel / Valeo” air conditioner compressor ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - Refrigerant circuit (vehicle-specific Work‐
shop Manual) and ⇒ Electronic parts catalogue
Capacity for Audi A3 (8L_) 1997 to 2004
Vehicle Production period Capacity in Differing characteristics of this refrigerant circuit
model grammes
Audi A3 From 08.96 onwards 750 + 50 • None

Note

♦ Exclusive use was made at the start of production of “Sanden”

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 297
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Capacity for Audi TT (8N_) 1999 ►

Vehicle Production period Capacity in Differing characteristics of this refrigerant circuit
model grammes
Audi TT From 10.98 750 + 50 • Condenser with flat tube width of 20 mm
to 10.03 (and from ⇒ page 299
06.04 to 08.04
⇒ page 298 )
From 10.03 onwards 650 + / - 20 • Condenser with flat tube width of 16 mm
(except 06.04 to ⇒ page 299
08.04 ⇒ page 298 )

Note

♦ Exclusive use was made at the start of production of “Sanden”

air conditioner compressors. With effect from Model Year
1999, use has also been made of “Zexel / Valeo” air condi‐
tioner compressors ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit; System overview - Refrigerant circuit (ve‐
hicle-specific Workshop Manual) and ⇒ Electronic parts cata‐
logue .
♦ 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 299 . 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 grammes of refrigerant. These vehicles were also
provided with a sticker showing the incorrect capacity - namely
750 grammes (or 700 grammes in 06.04) instead of 650
grammes ⇒ page 299 . Under certain ambient conditions (e.g.
high ambient temperatures), over-filling of the systems may
result in the air conditioner compressor being shut off on ac‐
count of excess pressure in the refrigerant circuit. Complaints
may also be received about engine performance (e.g. hum‐
ming and drumming; the engine is subjected to greater load
as the air conditioner compressor constantly has to cope with
excessively high pressure). Remedy: Discharge the refriger‐
ant circuit, 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 ca‐
pacity 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 .

298 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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_.

Characteristics of refrigerant circuit:

• Expansion valve
• Receiver
• “Denso”, “Delphi”, “Sanden” or “Zexel / Valeo” air conditioner
compressor with air conditioner compressor regulating valve -
N280- ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit; System overview - Refrigerant circuit (vehicle-specific
Workshop Manual) and ⇒ Electronic parts catalogue
Vehicle model Production period Capacity in grammes Differing characteristics of this refrigerant
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; System overview - Re‐
frigerant circuit (vehicle-specific Work‐
shop Manual).

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 299
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Air conditioner with refrigerant R134a - Edition 11.2014

Vehicle model Production period Capacity in grammes Differing characteristics of this refrigerant
circuit
Audi Q3 (and From 07.11 on‐ 520 + / - 20 • None
RS Q3) wards

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 exclusive use was made of type “7
SEU 16” air conditioner compressors from “Denso”. With ef‐
fect from Model Year 2004 a gradual change was made to a
different “Denso” compressor (type “7 SEU 17”).
♦ With effect from Model Year 2004, “Zexel / Valeo” (type
“DSC17E”) and “Sanden” (type “PXE16”) air conditioner com‐
pressors were gradually introduced depending on the engine
⇒ Electronic parts catalogue and ⇒ Heating, air conditioning;
Rep. gr. 87 ; Refrigerant circuit; System overview - Refrigerant
circuit (vehicle-specific Workshop Manual).
♦ With effect from Model Year 2008, “Denso” (type “6 SEU 14”)
and “Delphi” air conditioner compressors were gradually in‐
troduced depending on the engine ⇒ Electronic parts cata‐
logue and ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit; System overview - Refrigerant circuit (ve‐
hicle-specific 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).

10.1.5 Capacities for Audi A3 (8V_ or 85_ for

China) 2013 ►, Audi A3 e-tron (8V_ )
2015 ►

Note

The capacity for the Audi A3 (8V_ or 85_ for China) applies to all
versions (saloon, Sportback, cabriolet, etc.)

Characteristics of refrigerant circuit:

• Expansion valve
• Receiver
• Mechanically driven “Denso” or “Sanden” air conditioner com‐
pressor with air conditioner compressor regulating valve -
N280- ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit; System overview - Refrigerant circuit (vehicle-specific
Workshop Manual) and ⇒ Electronic parts catalogue (all ve‐
hicles except A3 e-tron)
• On vehicles with a high-voltage system (A3 e-tron), electrically
driven “Sanden” or “Visteon” air conditioner compressors ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - Refrigerant circuit (vehicle-specific Work‐
shop Manual) and ⇒ Electronic parts catalogue

300 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Vehicle model Production period Capacity in grammes Differing characteristics of this refrigerant
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 the heat ex‐
changer for high-voltage battery (chiller)

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 ; Refrigerant circuit; System overview - refrigerant cir‐
cuit (vehicle-specific Workshop Manual).
♦ As of 11.2012, the quantity of refrigerant oil for the “Denso” air
conditioner compressor was 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 A3 (8V_ or 85_ for China) 2013
►, Audi A3 e-tron (8V_ ) 2015 ►”, page 342 . Then enter the
refrigerant oil capacity on the label in waterproof ink ⇒ Heat‐
ing, air conditioning; Rep. gr. 87 ; Installation location over‐
view - Air conditioning (vehicle-specific Workshop Manual)
and fill the refrigerant circuit with the quantity of refrigerant in‐
dicated above.

10.1.6 Capacities for Audi TT (8J_) 2007 ►

Characteristics of refrigerant circuit:
• Expansion valve
• Receiver
• “Denso”, “Delphi” or “Sanden” air conditioner compressor with
air conditioner compressor regulating valve - N280- ⇒ Heat‐
ing, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System
overview - Refrigerant circuit (vehicle-specific Workshop Man‐
ual) and ⇒ Electronic parts catalogue
Vehicle model Production period Capacity in grammes Differing characteristics of this refrigerant
circuit
Audi TT From 08.06 on‐ 525 + / - 25 • None
• With 4 or wards
6-cyl. en‐
gine

Audi TT From 03.09 on‐ 500 + / - 25 • Different type of condenser fitted ⇒

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 301
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 ;
Refrigerant circuit; System overview - Refrigerant circuit (ve‐
hicle-specific Workshop Manual).
♦ As of Model Year 2008, air conditioner compressors manu‐
factured by “Sanden” (type “PXE16”) were also gradually in‐
troduced for certain engines. This air conditioner compressor
has no magnetic clutch (it is constantly driven by the engine)
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - Refrigerant circuit (vehicle-specific Work‐
shop Manual).
♦ 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‐
ditioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific Workshop Manual).

10.1.7 Capacities for Audi TT (FV_) 2015 ►

Characteristics of refrigerant circuit:
• Expansion valve
• Receiver
• Mechanically driven “Denso” or “Sanden” air conditioner com‐
pressor with air conditioner compressor regulating valve -
N280- ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit; System overview - refrigerant circuit (vehicle-specific
Workshop Manual) and ⇒ Electronic parts catalogue
Vehicle model Production period Capacity in grammes Differing characteristics of this refrigerant
circuit
Audi TT From 10.14 on‐ 500 + / - 15 • None
wards

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; System overview - refrigerant circuit (vehicle-
specific Workshop Manual).

10.1.8 Capacities for Audi 80 (8A_ / 8C_), Audi Coupé (8B_), Audi Cabriolet (8G_)
► 2002
Characteristics of refrigerant circuit:
• Restrictor (not coloured).
• Reservoir

302 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

• Air conditioner compressor from “Zexel / Valeo” ⇒ Heating, air

conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - Refrigerant circuit (vehicle-specific Workshop Manual)
and ⇒ Electronic parts catalogue
Vehicle model Production period Capacity in grammes Differing characteristics of this
refrigerant circuit
Audi 80 From 10.92 onwards 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 bore (1.54 mm) is yellow-coloured. The
restrictor with the larger bore (1.83 mm) is not coloured.
♦ 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).

10.1.9 Capacities for Audi A4 (8D_) 1995 ►

Note

Also applies to the Audi RS 4.

Characteristics of refrigerant circuit:

• Restrictor
• Reservoir
• “Denso” or “Zexel / Valeo” air conditioner compressor ⇒ Heat‐
ing, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System
overview - Refrigerant circuit (vehicle-specific Workshop Man‐
ual) and ⇒ Electronic parts catalogue
Vehicle model Production period Capacity in grammes Differing characteristics of this
refrigerant circuit
Audi A4 From 11.94 650 + 50 • Restrictor not coloured
to 11.97
From 11.97 onwards 700 + 50 • Restrictor coloured (yellow)
• “Showa/ Keihin” condenser
(distinguishing feature
⇒ page 305 )

From 11.98 onwards 550 + 50 • Restrictor coloured (yellow)

• “AWG” condenser (distin‐
guishing feature
⇒ page 305 )

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 303
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Vehicle model Production period Capacity in grammes Differing characteristics of this

refrigerant circuit
Audi RS 4 From 05.00 onwards 650 + 50 • Restrictor coloured (yellow)

Note

♦ Restrictors with a modified bore have been installed at the

factory since November 1997 (yellow-coloured). The capacity
was increased by 50 g for vehicles with a yellow-coloured re‐
strictor.
♦ In order to distinguish between the two restrictor versions, the
one with the smaller bore (1.54 mm) is yellow-coloured. The
restrictor with the larger bore (1.83 mm) is not coloured.
♦ 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.
♦ 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).
♦ 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.
♦ Depending on manufacturer, colour of red restrictor may tend
more towards orange.
♦ 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 305 .
♦ 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
(vehicle-specific Workshop Manual) and ⇒ Electronic parts
catalogue .

304 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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.

Characteristics of refrigerant circuit:

• 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 grammes 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

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 305
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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, fit
only red or yellow-coloured restrictors. Yellow-coloured re‐
strictors were fitted in model year 2001. Red-coloured restric‐
tors 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.
♦ 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 exclusive use was made of type “6
SEU 12” and “7 SEU 16” air conditioner compressors from
“Denso”. As of Model Year 2004, a gradual change was made
to other types of compressor manufactured by “Denso” (“6
SEU 14” and “7 SEU 17”) ⇒ Heating, air conditioning; Rep.
gr. 87 ; Refrigerant circuit; System overview - Refrigerant cir‐
cuit (vehicle-specific Workshop Manual) and ⇒ Electronic
parts catalogue .
♦ 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 .

306 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 .

Characteristics of refrigerant circuit:

• 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, depending on the engine) ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific Workshop Manual) and ⇒
Electronic parts catalogue (all vehicles except Audi Q5 hy‐
brid).
• On vehicles with a high-voltage system (Audi Q5 Hybrid),
electrically driven “Denso” air conditioner compressors ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - Refrigerant circuit (vehicle-specific Work‐
shop Manual) and ⇒ Electronic parts catalogue .
• Different condenser versions (and consequently also different
capacities for the refrigerant R134a)
♦ Capacity for Audi A4, Audi A5 and Audi A5 Cabriolet
⇒ page 308
♦ Capacity for Audi Q5 and Audi Q5 hybrid ⇒ page 311
♦ Capacity for Audi RS 4, Audi RS 5 ⇒ page 315
♦ Distinguishing features of condensers ⇒ page 316

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 307
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Audi A4, Audi A5 and Audi A5 Cabriolet

Note

♦ Also applies to the Audi S5.

♦ Capacity for Audi RS 5 Cabriolet ⇒ page 315

Vehicle model Production period Capacity in grammes Differing characteristics of this refrigerant
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 316 )
• For vehicles with 4, 6 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 316 )
• The “Denso” condensers are primarily
fitted in 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. engine from 10.13 onwards.

308 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Vehicle model Production period Capacity in grammes Differing characteristics of this refrigerant
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 316 )
• The condensers manufactured by
“Showa/Keihin” with part number 8T0
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/
Keihin” with part number 8T0 xxx xxx
and index “D” or later (distinguishing
features ⇒ page 316 )
♦ 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 316 )
• This condenser manufactured by
“Showa / Keihin” is currently only instal‐
led on vehicles produced in China.

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 309
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

♦ As of the product conversion in March 2012, the Audi A4 and

Audi A5 (except RS models) are no longer available 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 and 6-cyl. engine and type “7 SEU 17” for vehicles with
an 8-cyl. engine); these air conditioner compressors have no
magnetic clutch (they are constantly driven 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 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 ; Refrigerant circuit; System overview - Refrigerant
circuit (vehicle-specific Workshop Manual).
♦ As of Model Year 2012, air conditioner compressors were
gradually introduced for certain engines (e.g. in vehicles with
a 4-cyl. TDI engine) and versions which are additionally fitted
with an air conditioning system magnetic clutch - N25- at the
pulley (type “6 SAS 14”) ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit; System overview - Refrigerant circuit
(vehicle-specific Workshop Manual) and ⇒ Electronic parts
catalogue .
♦ Air conditioner compressors with an air conditioning system
magnetic clutch - N25- were gradually introduced for certain
4-cyl. TDI engines from August 2011 onwards ⇒ 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 349 ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐
frigerant circuit; System overview - Refrigerant circuit (vehicle-
specific Workshop Manual) and ⇒ Electronic parts catalogue
♦ 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. Distinguishing feature ⇒ page 316 .
♦ 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. Distinguishing feature ⇒ page 316 .

310 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

♦ 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 316 and ⇒ Electronic parts
catalogue .
♦ Distinguishing features of condensers ⇒ page 316

Audi Q5 and Audi Q5 hybrid

Note

Also applies for the Audi SQ5.

Vehicle model Production period Capacity in grammes Differing characteristics of this refrigerant
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”)
• Condenser with part number
8K0 xxx xxx, manufactured by “Denso”
or “Showa / Keihin” (distinguishing fea‐
tures ⇒ page 316 )

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 311
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Vehicle model Production period Capacity in grammes Differing characteristics of this refrigerant
circuit
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 316 )
• 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). Distinguishing feature
⇒ page 316 .
• The condensers manufactured by
“Showa/Keihin” with part number 8T0
xxx xxx and index “D” or later will be
gradually installed in all vehicles from
10.13 onwards.

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/
Keihin” with part number 8T0 xxx xxx
and index “C” or earlier (distinguishing
features ⇒ page 316 )
• The condensers manufactured by
“Showa/Keihin” with part number 8T0
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‐

312 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Vehicle model Production period Capacity in grammes Differing characteristics of this refrigerant
circuit
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)
• Condenser with part number
8KD xxx xxx, manufactured by “Showa /
Keihin” (distinguishing features
⇒ page 316 )
• The condenser manufactured by
“Showa/Keihin” is currently only instal‐
led on vehicles 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.

Audi Q5 hy‐ From 05.11 to 840 +/- 20 (see notes) • Electrically driven air conditioner com‐
brid 07.12 (see notes) pressor
• Condenser with part number
8R0 xxx xxx, manufactured by
“Denso” (distinguishing features
⇒ page 316 )
• Operating and display unit for the air
conditioning, the control unit for Clima‐
tronic - J255- with part number 8Rx xxx
xxx and an air conditioning unit with part
number 8Kx xxx xxx ⇒ Electronic parts
catalogue and ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Refrigerant circuit;
System overview - Refrigerant circuit
(vehicle-specific Workshop Manual).
• 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 316 )
900 g (see notes).
• Operating and display unit for the air
conditioning, the control unit for Clima‐
tronic - J255- with part number 8Kx xxx
xxx and an air conditioning unit with part
number 8Tx xxx xxx ⇒ Electronic parts
catalogue and ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Refrigerant circuit;
System overview - Refrigerant circuit
(vehicle-specific Workshop Manual).
• With second evaporator in battery cool‐
ing module

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 313
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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
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 ;
Refrigerant circuit; System overview - Refrigerant circuit (ve‐
hicle-specific Workshop Manual).
♦ As of Model Year 2012, air conditioner compressors were
gradually introduced for certain engines (e.g. in vehicles with
a 4-cyl. TDI engine) and versions which are additionally fitted
with an air conditioning system magnetic clutch - N25- at the
pulley (type “6 SAS 14”) ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit; System overview - Refrigerant circuit
(vehicle-specific Workshop Manual) and ⇒ Electronic parts
catalogue .
♦ Air conditioner compressors with an air conditioning system
magnetic clutch - N25- were gradually introduced for certain
4-cyl. TDI engines from August 2011 onwards ⇒ Electronic
parts catalogue .
♦ From June 2012 onwards, the refrigerant circuit (air condition‐
er 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 349 ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐
frigerant circuit; System overview - Refrigerant circuit (vehicle-
specific Workshop Manual) and ⇒ Electronic parts catalogue
♦ 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. Distinguishing feature ⇒ page 316 .
♦ 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. Distinguishing feature ⇒ page 316 .
♦ 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).

314 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

♦ 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 316 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.
♦ Distinguishing features of condensers ⇒ page 316

Audi RS 4, Audi RS 5

Note

Also applies for the Audi RS 5 Cabriolet.

Vehicle model Production period Capacity in grammes Differing characteristics of this refrigerant
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
• Condenser with part number
8K0 xxx xxx, manufactured by
“Denso” (distinguishing features
⇒ page 316 )

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 315
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

♦ The air conditioner compressors fitted at the start of production

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;
Rep. gr. 87 ; Refrigerant circuit; System overview - Refrigerant
circuit (vehicle-specific Workshop 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 for 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 cer‐
tain 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 54 .
♦ 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 54 ; for the correct version refer to the ⇒ Electronic
parts catalogue .

316 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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,
air conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - Refrigerant circuit (vehicle-specific Workshop Manual).

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;
Rep. gr. 87 ; Refrigerant circuit; System overview - Refrigerant
circuit (vehicle-specific Workshop Manual).

Note

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 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 100 / Audi A6 (4A_) ► 1998

Characteristics of refrigerant circuit:
• Restrictor not coloured
• Reservoir
• “Denso” or “Zexel / Valeo” air conditioner compressor ⇒ Heat‐
ing, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System
overview - Refrigerant circuit (vehicle-specific Workshop Man‐
ual) and ⇒ Electronic parts catalogue
Vehicle mod‐ Production period Capacity in grammes Differing characteristics of this refriger‐
el ant circuit
Audi 100 / From 10.92 750 + 50 • None
Audi A6 to 03.97

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 317
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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, check the capacity
specified on the label in the vehicle and amend if necessary,
or replace the existing label with one indicating the correct ca‐
pacity (affix over old label).
♦ Restrictors with modified bore (coloured) have been installed
at the factory since November 1997. In order to distinguish
between the two restrictor versions, the one with the smaller
bore (1.54 mm) is yellow-coloured. The restrictor with the larg‐
er bore (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 .

10.1.13 Capacities for Audi A6 (4B_) 1998 ► and Audi allroad (4B_) ► 2005
Characteristics of refrigerant circuit:
• 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

318 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Vehicle model Production period Capacity in grammes Differing characteristics of this refrigerant
circuit
Audi A6 From 04.97 800 + 50 • Restrictor not coloured
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 323

From 11.97 850 + 50 • Restrictor coloured (yellow)

to 08.98
• 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 323

Note

♦ Restrictors with a modified bore have been installed at the

factory since November 1997 (yellow-coloured). The capacity
was increased by 50 g for vehicles in which a yellow-coloured
restrictor was installed.
♦ In order to distinguish between the two restrictor versions, the
one with the smaller bore (1.54 mm) is yellow-coloured. The
restrictor with the larger bore (1.83 mm) is not coloured.
♦ If a vehicle is fitted with a coloured restrictor as replacement
for a non-coloured restrictor, add 50 g more refrigerant (refer
to table). In addition, check the capacity specified on the label
in the vehicle and amend if necessary, or replace the existing
label 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 conditioner 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 .
♦ 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).

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 319
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Vehicle model Production period Capacity in grammes 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 323 ) ⇒ 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 323 ) ⇒ Electronic parts
catalogue .

Vehicle model Production period Capacity in grammes Differing characteristics of this refrigerant
circuit
Audi A6/Audi ♦ From 10.98 to 12.98 550 + 50 • Restrictor coloured (yellow)
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
conditioning (vehicle-specific Work‐
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 323 ) and ⇒ Electronic parts
catalogue

Audi A6/Audi From 04.99 onwards 650 + 50 • Restrictor coloured (yellow)

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
conditioning (vehicle-specific Work‐
• 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 323 ) and ⇒ Elec‐
• With 6-cyl. tronic parts catalogue .
diesel en‐
gine (see
notes)

320 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Vehicle model Production period Capacity in grammes Differing characteristics of this refrigerant
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 ;
Installation location overview - Air
• 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 323 )
and ⇒ Electronic parts catalogue .
• 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 323 .
♦ The Audi A6 is fitted with different air conditioner compressors
depending on the engine and production period.
♦ 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
⇒ Electronic parts catalogue .
♦ Vehicles as of 04.99 with 6-cyl. diesel engine may be fitted
with a condenser with index “D”, “G”, “R” or “K”. Observe the
different capacities ⇒ Heating, air conditioning; Rep. gr. 87 ;
Installation location overview - Air conditioning (vehicle-spe‐
cific Workshop Manual) and ⇒ Electronic parts catalogue .

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 321
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Vehicle model Production period Capacity in grammes Differing characteristics of this refrigerant
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
conditioning (vehicle-specific Work‐
shop Manual).
• Condenser with part no. 4B3 260 401
(403) B, D, E (flat tube dimensions 18
mm x 1.7 mm ⇒ page 323 ) ⇒ Elec‐
tronic parts catalogue .

Audi A6 From 03.99 to 02.00 650 + 50 • Restrictor coloured (yellow)

• With 8-cyl.
engine • Air conditioner unit version “2” ⇒
Heating, air conditioning; Rep. gr. 87 ;
Installation location overview - Air
conditioning (vehicle-specific Work‐
shop Manual).
• Condenser with part no. 4B3 260 401
(403) C (flat tube dimensions 18 mm
x 1.7 mm ⇒ page 323 ) ⇒ 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
location overview - Air conditioning (vehicle-specific Work‐
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‐
cific Workshop Manual) and ⇒ Electronic parts catalogue .

322 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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
⇒ Electronic parts catalogue .

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
⇒ Electronic parts catalogue .

10.1.14 Capacities for Audi A6 (4F_) 2005 ►

Note

Also applies to the Audi S6 and Audi RS 6.

Characteristics of refrigerant circuit:

• Restrictor (red-coloured).
• Reservoir
• “Denso” air conditioner compressor with air conditioner com‐
pressor regulating valve - N280- (no magnetic clutch)

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 323
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Vehicle Production period Capacity in grammes 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

♦ 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, only
fit red-coloured restrictors.
♦ Different air conditioner compressors are fitted depending on
the model ⇒ Heating, air conditioning; Rep. gr. 87 ; Installation
location overview - Air conditioning (vehicle-specific Work‐
shop Manual) and ⇒ Electronic parts catalogue .
♦ 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 .

10.1.15 Capacities for Audi A6 (4G_ or 4X_ for

China ) 2011 ►, Audi A7 (4G_ or 4X_ for
China) 2011 ►, Audi A6 Hybrid (4G_)
2012 ►

Note

♦ Also applies to Audi S and RS models.

♦ RS models are fitted with a shallower condenser ⇒ Heating,
air conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - Refrigerant circuit (vehicle-specific Workshop Manual)
and ⇒ Electronic parts catalogue .

Characteristics of refrigerant circuit:

324 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

view - Refrigerant circuit (vehicle-specific Workshop Manual)

and ⇒ Electronic parts catalogue .
Vehicle model Production period Capacity in grammes Differing characteristics of this refrigerant
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‐ 530+ / - 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
• With second evaporator in battery cool‐
ing module

Note

♦ On certain versions for China the type designation 4X_ is used

instead of 4G_.
♦ At the start of production, all vehicles except the Audi A6 hybrid
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‐
tioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific Workshop Manual).
♦ At the start of production, the Audi A6 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.
♦ 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 .

10.1.16 Capacities for Audi V8 (4C_) ► 1994

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 325
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

view - Refrigerant circuit (vehicle-specific Workshop Manual)

and ⇒ Electronic parts catalogue
Vehicle mod‐ Production period Capacity in grammes Differing characteristics of this refriger‐
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 bore are coloured (yellow or red). The
red-coloured restrictor is not to be used for these vehicles.
♦ Depending on manufacturer, colour of red restrictor may tend
more towards orange.
♦ 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).

10.1.17 Capacities for Audi A8 (4D_) 1994 ►

Characteristics of refrigerant circuit:
• Restrictor
• Reservoir
• “Denso” or “Zexel / Valeo” air conditioner compressor ⇒ Heat‐
ing, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System
overview - Refrigerant circuit (vehicle-specific Workshop Man‐
ual) and ⇒ Electronic parts catalogue
Vehicle mod‐ Production period Capacity in grammes Differing characteristics of this refriger‐
el ant circuit
Audi A8 From 05.94 750 + 50 • Restrictor not coloured
to 11.97
From 11.97 onwards 800 + 50 • Restrictor coloured (yellow)

326 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

♦ Restrictors with a modified bore have been installed at the

factory since November 1997 (yellow-coloured). The capacity
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 bore is coloured yellow (1.54 mm) or
red (1.42 mm). The restrictor with the larger bore (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). 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
red-coloured restrictor is not to be used for these vehicles.
♦ Exclusive use was made at the start of production of “Zexel /
Valeo” air conditioner compressors. As of Model Year 1996,
production was gradually switched to “Denso” air conditioner
compressors ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐
frigerant circuit; System overview - Refrigerant circuit (vehicle-
specific Workshop Manual) and ⇒ Electronic parts catalogue .
♦ 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).

10.1.18 Capacities for Audi A8 (4E_) 2003 ►

Characteristics of refrigerant circuit:
• Restrictor (red-coloured).
• Reservoir
• “Denso” air conditioner compressor with air conditioner com‐
pressor regulating valve - N280- (no magnetic clutch) ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - Refrigerant circuit (vehicle-specific Work‐
shop Manual).
Vehicle mod‐ Production period Capacity in grammes Differing characteristics of this refriger‐
el ant circuit
Audi A8 From 10.02 onwards 620 + / - 20 • Red-coloured restrictor

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 327
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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, only
fit red-coloured restrictors.
♦ Different air conditioner compressors are fitted depending on
the model ⇒ Heating, air conditioning; Rep. gr. 87 ; Refriger‐
ant circuit; System overview - Refrigerant circuit (vehicle-spe‐
cific Workshop Manual) and ⇒ Electronic parts catalogue .

10.1.19 Capacities for Audi A8 (4H_) 2010 ►, Audi A8 hybrid (4H_) 2012 ►
Characteristics of refrigerant circuit:
• Expansion valve
• With one or two evaporator(s) depending on equipment
• Refrigerant line with internal heat exchanger
• Desiccant cartridge in receiver at condenser
• Mechanically driven “Denso” air conditioner compressor with
air conditioner compressor regulating valve - N280- ⇒ Heat‐
ing, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System
overview - Refrigerant circuit (vehicle-specific Workshop Man‐
ual) and ⇒ Electronic parts catalogue (all vehicles except Audi
A8 hybrid).
• On vehicles with a high-voltage system (Audi A8 Hybrid), elec‐
trically driven “Denso” air conditioner compressors ⇒ Heating,
air conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - Refrigerant circuit (vehicle-specific Workshop Manual)
and ⇒ Electronic parts catalogue .

Caution

Different refrigerant and refrigerant oil capacity for vehicles

with an 8-cyl. TDI engine
♦ On account of the installation position of the air conditioner
compressor (at the top of the engine), the quantity of re‐
frigerant oil differs on vehicles with an 8-cyl. TDI engine
from that on the rating plate of the air conditioner com‐
pressor.

Vehicle model Production period Capacity in grammes Differing characteristics of this refrigerant
circuit
Audi A8 (all From 03.10 on‐
except 8-cyl. wards
TDI engine)
♦ Vehicle 780 + / - 20 • One evaporator
with one
evaporator

328 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Vehicle model Production period Capacity in grammes Differing characteristics of this refrigerant
circuit
♦ 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

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

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 329
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

♦ On vehicles with a 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.
♦ At the start of production, all vehicles except the Audi A8 hybrid
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‐
tioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific Workshop Manual).
♦ At the start of production, the Audi A8 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.
♦ At the start of production, the Audi A8 hybrid was fitted with an
air conditioner compressor with a refrigerant oil quantity of
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).

10.1.20 Capacities for Audi Q7 (4L_) 2006 ►

Characteristics of refrigerant circuit:
• Expansion valve
• With one or two evaporator(s) depending on equipment
• Desiccant cartridge in receiver at condenser
• “Denso” air conditioner compressor with air conditioner com‐
pressor regulating valve - N280- ⇒ Heating, air conditioning;
Rep. gr. 87 ; Refrigerant circuit; System overview - Refrigerant
circuit (vehicle-specific Workshop Manual) and ⇒ Electronic
parts catalogue
Vehicle model Production period Capacity in grammes Differing characteristics of this refrigerant
circuit
Audi Q7 From 02.06 on‐
wards
♦ Vehicle 700 + 50 • One evaporator
with one
evaporator

330 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Vehicle model Production period Capacity in grammes Differing characteristics of this refrigerant
circuit
♦ Vehicle 1050 + 50 • Two evaporators
with two
evapora‐
tors

10.1.21 Capacities for Audi R8 (42_) 2008 ►

Characteristics of refrigerant circuit:
• Restrictor (red-coloured).
• Reservoir
• Two series-connected condensers
• “Denso” air conditioner compressor with air conditioner com‐
pressor regulating valve - N280- ⇒ Heating, air conditioning;
Rep. gr. 87 ; Refrigerant circuit; System overview - Refrigerant
circuit (vehicle-specific Workshop Manual) and ⇒ Electronic
parts catalogue
Vehicle mod‐ Production period Capacity in grammes Differing characteristics of this refriger‐
el ant circuit
Audi R8 From 03.07 to 11.12 680 + / - 20 • Red-coloured restrictor
♦ 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

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 331
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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, only
fit red-coloured restrictors.
♦ 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‐
tronic parts catalogue and ⇒ Heating, air conditioning; Rep.
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
⇒ “10.2.23 Capacities for Audi R8 (42_) 2008 ►”, page 371 .

10.2 Approved refrigerant oils and refrigerant

oil capacities

Note

♦ As PAG (polyalkylene glycol) oil is highly hygroscopic (attracts

water), re-seal opened containers immediately so that they are
air-tight.
♦ PAG oil from containers which have been open for a lengthy
period is no longer usable.

♦ Approved refrigerant oils ⇒ page 333

♦ Refrigerant oil capacities ⇒ page 335

332 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 refrigerant oil developed specially and exclusively for
R134a refrigerant circuits is not commercially available.
♦ Refrigerant oils specifically designed for each air conditioner
compressor can therefore be obtained from the replacement
parts range ⇒ Electronic parts catalogue .
♦ If a defective air conditioner compressor is replaced by a com‐
pressor from a different manufacturer, it is important to check
whether the refrigerant oil already in the refrigerant circuit
(from the removed compressor) is also approved for the new
compressor. If a different refrigerant oil is approved for the new
air conditioner compressor than for the removed compressor,
the refrigerant circuit must be flushed
⇒ “5.5 Cleaning (flushing) refrigerant circuit with refrigerant
R134a”, page 116 .
♦ The use of other refrigerant oils may lead to system failure, as
miscibility and thus also circulation with the refrigerant R134a
(for air conditioner compressor lubrication) cannot always be
guaranteed.
♦ There are different refrigerant oils for “Zexel / Valeo”, “Denso”,
“Delphi” and “Sanden” compressors. ⇒ Electronic parts cata‐
logue
♦ 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).
♦ The refrigerant oil (G 052 300 A2) for use in refrigerant circuits
with “Denso” air conditioner compressors (old name “Nippon‐
denso”) is also included in the retrofit kit (part number 4A0 298
107 A). It is the same for mechanically and electrically driven
air conditioner compressors ⇒ Electronic parts catalogue .
♦ For refrigerant circuits with “Zexel/Valeo” air conditioner com‐
pressors, use refrigerant oil with part no. G 052 154 A2 ⇒
Electronic parts catalogue .
♦ For refrigerant circuits with mechanically driven “Sanden” air
conditioner compressors, use refrigerant oil with part no. G
052 154 A2 ⇒ Electronic parts catalogue .
♦ 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 M ⇒ Electronic
parts catalogue .
♦ Use can be made for refrigerant circuits with a “Delphi” com‐
pressor of refrigerant oil with part no. G 052 154 A2 and
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 refrigeration oil (G 052
154 A2) and the refrigeration oil (G 052 200 A2) contained in
the retrofit kit (part no. 4A0 298 107) ⇒ Electronic parts cata‐
logue .

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 333
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

♦ 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 .
♦ 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 68 before evacuating the refrigerant circuit. This
can make sense if e.g. a refrigerant oil that is normally only
rarely used is prescribed for a refrigerant circuit. The refriger‐
ant oil added must always be fresh
⇒ “2.8 Refrigerant oil”, page 19 and ⇒ Electronic parts cata‐
logue . The positioning of service connection -1- or -2- in the
vehicle is different ⇒ Heating, air conditioning; Rep. gr. 87 ;
Installation location overview - Air conditioning (vehicle-spe‐
cific Workshop Manual).

334 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

10.2.2 Refrigerant oil capacities

Note

♦ For air conditioner compressor assignment (“Zexel / Valeo”,

“Sanden” or “Denso”), refer to the vehicle-specific Workshop
Manual ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit; System overview - Refrigerant circuit and ⇒ Electronic
parts catalogue
♦ 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).
♦ 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. If the air
conditioner compressor is renewed, the quantity of refrigerant
oil in the air conditioner compressor to be fitted therefore has
to be adjusted (an incorrect refrigerant oil quantity would dam‐
age 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
⇒ “5.5.2 Flushing electrically driven air conditioner compressor
(removing refrigerant oil)”, page 134 .
♦ On initial switch-on, the refrigerant oil is distributed throughout
the refrigerant circuit.
♦ Unless otherwise stated, the refrigerant oil capacities specified
also apply to the corresponding “S” and “RS” versions of this
vehicle model.
♦ For refrigerant oil topping-up quantities on renewing defective
refrigerant circuit components, refer to ⇒ page 270 . Also ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - Refrigerant circuit (vehicle-specific Work‐
shop Manual) and ⇒ Electronic parts catalogue

♦ ⇒ “10.2.3 Capacities for Audi A1 (8X_) 2011 ►”, page 336

♦ ⇒ “10.2.4 Capacities for Audi A2 (8Z_) 2001 ►”, page 339
♦ ⇒ “10.2.5 Capacities for Audi A3 (8L_) 1997 ► and Audi TT
(8N_) 1999 ►”, page 339
♦ ⇒ “10.2.6 Capacities for Audi A3 (8P_) 2004 ►, Audi Q3 (8U_
or 84_ for China) 2012 ►”, page 340
♦ ⇒ “10.2.7 Capacities for Audi A3 (8V_ or 85_ for China) 2013
►, Audi A3 e-tron (8V_ ) 2015 ►”, page 342
♦ ⇒ “10.2.8 Capacities for Audi TT (8J_) 2007 ►”, page 343
♦ ⇒ “10.2.9 Capacities for Audi TT (FV_) 2015 ►”, page 345
♦ ⇒ “10.2.10 Capacities for Audi 80 (8A_/8C_), Audi Coupé
(8B_), Audi Cabriolet (8G_) ► 2002”, page 346
♦ ⇒ “10.2.11 Capacities for Audi A4 (8D_) 1995 ►”, page 347

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 335
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

♦ ⇒ “10.2.12 Capacities for Audi A4 (8E_) 2001 ►, Audi A4 Cab‐

riolet (8H_) 2003 ►”, page 347
♦ ⇒ “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 ►”, page 349
♦ ⇒ “10.2.14 Capacities for Audi 100 / Audi A6 (4A_) ► 1998”,
page 356
♦ ⇒ “10.2.15 Capacities for Audi A6 (4B_) 1998 ► and Audi all‐
road ► 2005”, page 357
♦ ⇒ “10.2.16 Capacities for Audi A6 (4F_) 2005 ►”, page 360
♦ ⇒ “10.2.17 Capacities for Audi A6 (4G_ or 4X_ for China ) 2011
►, Audi A7 (4G_ or 4X_ for China) 2011 ►, Audi A6 Hybrid
(4G_) 2012 ►”, page 361
♦ ⇒ “10.2.18 Capacities for Audi V8 (4C_) ► 1994”, page 363
♦ ⇒ “10.2.19 Capacities for Audi A8 (4D_) 1994 ►”, page 363
♦ ⇒ “10.2.20 Capacities for Audi A8 (4E_) 2003 ►”, page 364
♦ ⇒ “10.2.21 Capacities for Audi A8 (4H_) 2010 ►, Audi A8 hybrid
(4H_) 2012 ►”, page 365
♦ ⇒ “10.2.22 Capacities for Audi Q7 (4L_) 2006 ►”, page 369
♦ ⇒ “10.2.23 Capacities for Audi R8 (42_) 2008 ►”, page 371

10.2.3 Capacities for Audi A1 (8X_) 2011 ►

Characteristics of refrigerant circuit:
• Expansion valve
• Receiver
• Air conditioner compressors from different manufacturers with
air conditioner compressor regulating valve - N280- (no mag‐
netic clutch) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
erant circuit; System overview - Refrigerant circuit (vehicle-
specific Workshop Manual) and ⇒ Electronic parts catalogue
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”), part number “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)
75+ / - 10 75+ / - 10 Air conditioner compres‐
sor manufactured by “San‐
den”, 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”

336 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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
110 + / - 10 110 + / - 10 • Air conditioner com‐
pressor manufactured
by “Delphi”, part num‐
ber “5K0 xxx xxx” or
“5Q0 xxx xxx”

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 337
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 270 .
♦ Different air conditioner compressors are fitted depending on
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 ⇒ Electronic parts catalogue and
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - Refrigerant circuit (vehicle-specific Work‐
shop Manual).
♦ 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‐
tioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific 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‐
tronic 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‐
ing; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific Workshop Manual) and ⇒
Electronic parts catalogue .
♦ The different oil quantities in the air conditioner compressor
may result from the design of the air conditioner compressor
(with or without oil separator at high-pressure connection) or,
in the case of identical air conditioner compressors, from the
design of the refrigerant circuit. Note these oil quantities. Too
much oil in the circuit results in higher pressures and a reduced
cooling output of the system. Too little oil may lead to lubrica‐
tion 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.
♦ As of 11.2012, the quantity of refrigerant oil for the “Denso” air
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 295 .

338 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

10.2.4 Capacities for Audi A2 (8Z_) 2001 ►

Characteristics of refrigerant circuit:
• Restrictor
• Reservoir
• Air conditioner compressor with air conditioner compressor
regulating valve - N280- (no magnetic clutch)
• Air conditioner compressor from “Denso” ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific Workshop 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

♦ 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 270 .
♦ As the air conditioner compressor and engine always operate
at the same time and the entire quantity of refrigerant oil is
contained in the air conditioner compressor, the circuit must
be completely assembled before starting the engine ⇒ Heat‐
ing, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System
overview - Refrigerant circuit (vehicle-specific Workshop Man‐
ual).
♦ 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 ►
Characteristics of refrigerant circuit:
• Expansion valve
• Receiver
• “Sanden” or “Zexel / Valeo” air conditioner compressor ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - Refrigerant circuit (vehicle-specific Work‐
shop Manual) and ⇒ Electronic parts catalogue
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 onwards 135 + / -15 135+/-15
Audi TT From 10.98 onwards 135 + / -15 135+/-15

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 339
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 270 .
♦ Exclusive use was made at the start of production of “Sanden”
air conditioner compressors. Since Model Year 1999, “Zexel /
Valeo” air conditioner compressors have also been used ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - Refrigerant circuit (vehicle-specific Work‐
shop Manual) and ⇒ Electronic parts catalogue .
♦ 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).

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_.

Characteristics of refrigerant circuit:

• Expansion valve
• Receiver
• Air conditioner compressors from different manufacturers with
air conditioner compressor regulating valve - N280- (no mag‐
netic clutch) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
erant circuit; System overview - Refrigerant circuit (vehicle-
specific Workshop Manual) and ⇒ Electronic parts catalogue
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 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 • “Sanden” air condition‐

er compressor

140 + / - 10 140 + / - 10 “Denso” air conditioner

compressor of “7 SEU 17”
type
From 06.07 90 + / - 10 90 + / - 10 • “Denso” air conditioner
onwards compressor of “6 SEU
14” type

340 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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
From 08.07 110 + / - 10 110 + / - 10 • “Delphi” air conditioner
onwards compressor

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 270 .
♦ Different air conditioner compressors are fitted depending on
the production period and engine.
♦ At the start of production, exclusive use was made of air con‐
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 .
♦ 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).
♦ With effect from Model Year 2008, “Denso” (type “6 SEU 14”)
and “Delphi” air conditioner compressors were gradually in‐
troduced depending on the engine ⇒ Electronic parts cata‐
logue and ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit; System overview - Refrigerant circuit (ve‐
hicle-specific Workshop 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 ;
Refrigerant circuit; System overview - refrigerant circuit (vehi‐
cle-specific Workshop Manual) and ⇒ Electronic parts cata‐
logue .
♦ 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. Note these oil quantities. Too
much oil in the circuit results in higher pressures and a reduced
cooling output of the system. Too little oil may lead to lubrica‐
tion 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.

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 341
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

10.2.7 Capacities for Audi A3 (8V_ or 85_ for

China) 2013 ►, Audi A3 e-tron (8V_ )
2015 ►

Note

The capacities for the Audi A3 (8V_ or 85_ for China) applies to
all versions (saloon, Sportback, cabriolet, etc.)

Characteristics of refrigerant circuit:

• Expansion valve
• Receiver
• Mechanically driven “Denso” or “Sanden” air conditioner com‐
pressor with air conditioner compressor regulating valve -
N280- ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit; System overview - Refrigerant circuit (vehicle-specific
Workshop Manual) and ⇒ Electronic parts catalogue (all ve‐
hicles except Audi A3 e-tron).
• On vehicles with a high-voltage system (Audi A3 e-tron), elec‐
trically driven “Sanden” or “Visteon” air conditioner compres‐
sors ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit; System overview - Refrigerant circuit (vehicle-specific
Workshop Manual) and ⇒ Electronic 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‐
ditioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
refrigerant circuit (vehicle-specific Workshop Manual).

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 A3 From 05.12 110 + / - 10 110 + / - 10 • “Denso” air conditioner
onwards compressor

75+ / - 10 75 + / - 10 • “Sanden” air condition‐

er compressor

110 + / - 10 110 + / - 10 • “Delphi” air conditioner

compressor

Audi A3 From 09.14 120 + / - 10 120 + / - 10 • Electrically driven air

e-tron onwards conditioner compres‐
sor
• With second evapora‐
tor in the heat exchang‐
er for high-voltage bat‐
tery
• Deviation in refrigerant
oil

342 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 270 .
♦ Different air conditioner compressors are fitted depending on
the production period and engine.
♦ 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 ;
Refrigerant circuit; System overview - refrigerant circuit (vehi‐
cle-specific Workshop Manual) and ⇒ Electronic parts cata‐
logue .
♦ 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.
♦ 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.
♦ As of 11.2012, the quantity of refrigerant oil for the “Denso” air
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 in waterproof ink ⇒ Heating,
air conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - Refrigerant circuit (vehicle-specific Workshop Manual)
and fill the refrigerant circuit with the quantity of refrigerant in‐
dicated above
⇒ “10.1.5 Capacities for Audi A3 (8V_ or 85_ for China) 2013
►, Audi A3 e-tron (8V_ ) 2015 ►”, page 300 .
♦ 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 M) ⇒ Electronic parts catalogue . Since the storage
tanks in most air conditioner service stations do not contain
this refrigerant, the refrigerant oil extracted when emptying 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 when a valve is removed
⇒ page 333
♦ 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 M ⇒ Electronic
parts catalogue .

10.2.8 Capacities for Audi TT (8J_) 2007 ►

Characteristics of refrigerant circuit:

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 343
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

• Expansion valve
• Receiver
• Air conditioner compressors from different manufacturers with
air conditioner compressor regulating valve - N280- (no mag‐
netic clutch) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐
erant circuit; System overview - Refrigerant circuit (vehicle-
specific Workshop Manual) and ⇒ Electronic parts catalogue
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 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

110 + / - 10 110 + / - 10 • “Delphi” air conditioner

compressor

344 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 270 .
♦ 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 ;
Refrigerant circuit; System overview - Refrigerant circuit (ve‐
hicle-specific Workshop Manual).
♦ As of Model Year 2008, air conditioner compressors manu‐
factured by “Sanden” (type “PXE16”) were also gradually in‐
troduced for certain engines. This air conditioner compressor
has no magnetic clutch (it is constantly driven by the engine)
⇒ Electronic parts catalogue and ⇒ Heating, air conditioning;
Rep. gr. 87 ; Refrigerant circuit; System overview - Refrigerant
circuit (vehicle-specific Workshop Manual).
♦ 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‐
ditioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific Workshop 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 ;
Refrigerant circuit; System overview - refrigerant circuit (vehi‐
cle-specific Workshop Manual) and ⇒ Electronic parts cata‐
logue .
♦ 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. Note these oil quantities. Too
much oil in the circuit results in higher pressures and a reduced
cooling output of the system. Too little oil may lead to lubrica‐
tion 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.

10.2.9 Capacities for Audi TT (FV_) 2015 ►

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 345
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

Various mechanically driven air conditioner compressors are fit‐

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 TT From 10.14 110 + / - 10 110 + / - 10 • “Denso” air conditioner
onwards compressor

75+ / - 10 75 + / - 10 • “Sanden” air condition‐

er compressor

110 + / - 10 110 + / - 10 • “Delphi” air conditioner

compressor

Note

♦ The replacement compressor contains the full quantity of oil

10.2.10 Capacities for Audi 80 (8A_/8C_), Audi Coupé (8B_), Audi Cabriolet (8G_)
► 2002
Characteristics of refrigerant circuit:
• Restrictor (not coloured).
• Reservoir
• Air conditioner compressor from “Zexel / Valeo” ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐

346 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

view - Refrigerant circuit (vehicle-specific Workshop Manual)

and ⇒ Electronic parts catalogue
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 80 From 10.92 onwards 250 + 50 250 + 50
Audi Coupé
Audi Cabrio‐
let

Note

♦ The replacement compressor contains the full quantity of oil

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 270 .
♦ 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).

10.2.11 Capacities for Audi A4 (8D_) 1995 ►

Characteristics of refrigerant circuit:
• Restrictor
• Reservoir
• “Denso” or “Zexel / Valeo” air conditioner compressor ⇒ Heat‐
ing, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System
overview - Refrigerant circuit (vehicle-specific Workshop Man‐
ual) and ⇒ Electronic parts catalogue
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 A4 From 11.94 onwards 250 + 50 250 + 50

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 270 .
♦ The Audi A4 is fitted with different air conditioner compressors
depending on the engine and production period ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - Refrigerant circuit (vehicle-specific Workshop Manual)
and ⇒ Electronic parts catalogue
♦ 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).

10.2.12 Capacities for Audi A4 (8E_) 2001 ►, Audi A4 Cabriolet (8H_) 2003 ►
Characteristics of refrigerant circuit:
• Restrictor

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 347
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

• Reservoir
• “Denso” air conditioner compressor with air conditioner com‐
pressor regulating valve - N280- (no magnetic clutch) ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - Refrigerant circuit (vehicle-specific Work‐
shop Manual) and ⇒ Electronic parts catalogue
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 A4 From 11.00 180 + / - 10 180 + / - 10 • Air conditioner com‐
Audi RS 4 to 01.04 pressor type “6 SEU
• All types 12” “6 SEU 14” “7 SEU
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)

348 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 270 .
♦ The Audi A4 is fitted with different air conditioner compressors
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
exact part number ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit; System overview - Refrigerant circuit (ve‐
hicle-specific Workshop Manual) and ⇒ Electronic parts cata‐
logue
♦ 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 .
♦ 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. Note these oil quantities. Too
much oil in the circuit results in higher pressures and a reduced
cooling output of the system. Too little oil may lead to lubrica‐
tion 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.

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

Characteristics of refrigerant circuit:

• Expansion valve
• Receiver

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 349
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

• 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- , depending on
the engine and production period) ⇒ Heating, air conditioning;
Rep. gr. 87 ; Refrigerant circuit; System overview - Refrigerant
circuit (vehicle-specific Workshop Manual) and ⇒ Electronic
parts catalogue (all vehicles except Audi Q5 hybrid).
• On vehicles with a high-voltage system (Audi Q5 Hybrid),
electrically driven “Denso” air conditioner compressors ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - Refrigerant circuit (vehicle-specific Work‐
shop Manual) and ⇒ Electronic parts catalogue .
♦ Capacity for Audi A4, Audi A5 and Audi A5 Cabriolet
⇒ page 350
♦ Capacity for Audi Q5 and Audi Q5 hybrid ⇒ page 352
♦ Capacity for Audi RS 4, Audi RS 5 ⇒ page 354
♦ General notes on quantity of refrigerant oil and refrigerant cir‐
cuit ⇒ page 356
Audi A4, Audi A5 and Audi A5 Cabriolet

Note

♦ Also applies to the Audi S5.

♦ Capacity for Audi RS 5 Cabriolet ⇒ page 354

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

350 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 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)

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 351
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

♦ As of the product conversion in March 2012, the Audi A4 and

Audi A5 (except RS models) are no longer available with 8-
cyl. engines.
♦ 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) ⇒ Heating,
air conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - Refrigerant circuit (vehicle-specific Workshop Manual)
and ⇒ Electronic parts catalogue
♦ From August 2011 onwards, air conditioners with air condi‐
tioning system magnetic clutch - N25- are gradually introduced
for certain 4-cyl. TDI engines ⇒ Electronic parts catalogue .
♦ 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)
⇒ “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 307 and ⇒ Electronic parts catalogue .
♦ Further notes ⇒ page 356

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
el cm3 compressor in circuit
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)

352 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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
el cm3 compressor in circuit
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”

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 353
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 307 , ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific Workshop Manual) and ⇒
Electronic parts catalogue
♦ 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 conditioners with air condi‐
tioning system magnetic clutch - N25- are gradually introduced
for certain 4-cyl. TDI engines ⇒ Electronic parts catalogue .
♦ 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)
⇒ “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 307 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.
♦ At the start of production, the Audi Q5 hybrid was fitted with
an air conditioner compressor with a refrigerant oil quantity of
160 ccm. Shortly after the start of production, the refrigerant
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 .
♦ Further notes ⇒ page 356

Audi RS 4, Audi RS 5

Note

Also applies for the Audi RS 5 Cabriolet.

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 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

354 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 ⇒ page 356

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 355
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Additional notes

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 270 .
♦ The air conditioner compressors fitted at the start of production
were manufactured by “Denso” (type “6 SEU 14” for vehicles
with 4 and 6-cyl. engine and type “7 SEU 17” for vehicles with
an 8-cyl. engine); these air conditioner compressors have no
magnetic clutch (they are constantly driven 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 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 ; Refrigerant circuit; System overview - Refrigerant
circuit (vehicle-specific Workshop Manual).
♦ On the Audi Q5 hybrid, an electrically driven air conditioner
compressor with integrated control electronics is installed.
♦ 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
engine) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant
circuit; System overview - Refrigerant circuit (vehicle-specific
Workshop Manual) and ⇒ Electronic 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‐
ing; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific Workshop Manual) and ⇒
Electronic parts catalogue .
♦ The different oil quantities in the air conditioner compressor
may result from the design of the air conditioner compressor
(with or without oil separator at high-pressure connection) or,
in the case of identical air conditioner compressors, from the
design of the refrigerant circuit. Note these oil quantities. Too
much oil in the circuit results in higher pressures and a reduced
cooling output of the system. Too little oil may lead to lubrica‐
tion 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.
♦ 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 100 / Audi A6 (4A_) ► 1998

Characteristics of refrigerant circuit:
• Restrictor

356 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

• Reservoir
• “Denso” or “Zexel / Valeo” air conditioner compressor ⇒ Heat‐
ing, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System
overview - Refrigerant circuit (vehicle-specific Workshop Man‐
ual) and ⇒ Electronic parts catalogue
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 100 / From 10.92 250 + 50 250 + 50
Audi A6 to 03.97

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 270 .
♦ 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. From model year 1996
onwards, “Denso” air conditioner compressors were gradually
introduced for vehicles with 6-cylinder engines ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - Refrigerant circuit (vehicle-specific Workshop Manual)
and ⇒ Electronic parts catalogue .
♦ 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).

10.2.15 Capacities for Audi A6 (4B_) 1998 ► and Audi allroad ► 2005
Characteristics of refrigerant circuit:
• Restrictor
• Reservoir
• “Denso” or “Zexel / Valeo” air conditioner compressor with air
conditioning system magnetic clutch - N25- ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - Refrigerant circuit (vehicle-specific Workshop Manual)
and ⇒ Electronic parts catalogue
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 l
• 6-cyl. petrol en‐
gine except 3.0 l

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 357
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 04.97 250 + 50 250 + 50 • Refer to notes be‐
road to 05.01 low.
• 4-cyl. diesel en‐
gine
• 6-cyl. diesel en‐
gine
(see notes for Audi
allroad)
Audi A6 From 04.97 on‐ 250 + 50 250 + 50 • Refer to notes be‐
• 8-cyl. engine wards low.
(with toothed All
belt camshaft
drive)

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 270 .
♦ The Audi A6 is fitted with different air conditioner compressors
depending on the engine and production period.
♦ 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.
gr. 87 ; Refrigerant circuit; System overview - Refrigerant cir‐
cuit (vehicle-specific workshop manual) and ⇒ Electronic
parts catalogue .
♦ 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).

Characteristics of refrigerant circuit:

358 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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. petrol en‐ type “6 SEU 12” or “7 SEU
gine 2.0 l 16” (refer to notes below)
• 6-cyl. petrol en‐
gine 3.0 l

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)
• 6-cyl. diesel en‐
gine
(see notes for Audi
allroad)
Audi allroad All 220 + 20 220 + 20 Air conditioner compressor
• 8-cyl. engine type “7 SEU 17” (refer to
(with chain-driven notes below)
camshaft)

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 270 .
♦ The Audi A6 is fitted with different air conditioner compressors
depending on the engine and production period.
♦ 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.
♦ As the replacement air conditioner compressor with air condi‐
tioner compressor regulating valve - N280- is supplied with
different oil capacities, the exact part no. must be observed ⇒
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - Refrigerant circuit (vehicle-specific Work‐
shop Manual) and ⇒ Electronic parts catalogue .
♦ The different oil quantities in the air conditioner compressor
may result from the design of the air conditioner compressor
(with or without oil separator at high-pressure connection) or,
in the case of identical air conditioner compressors, from the
design of the refrigerant circuit. Note these oil quantities. Too
much oil in the circuit results in higher pressures and a reduced
cooling output of the system. Too little oil may lead to lubrica‐
tion 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.

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 359
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

10.2.16 Capacities for Audi A6 (4F_) 2005 ►

Note

Also applies to the Audi S6 and Audi RS 6.

Characteristics of refrigerant circuit:

• Restrictor
• Reservoir
• “Denso” air conditioner compressor with air conditioner com‐
pressor regulating valve - N280- ⇒ Heating, air conditioning;
Rep. gr. 87 ; Refrigerant circuit; System overview - Refrigerant
circuit (vehicle-specific Workshop Manual) and ⇒ Electronic
parts catalogue
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 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

♦ 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.
♦ The Audi A6 is fitted with different air conditioner compressors
depending on the engine and production period.
♦ This air conditioner compressor is available as a replacement
part in different versions, so it is important to pay attention to
the exact part number ⇒ Heating, air conditioning; Rep. gr.
87 ; Refrigerant circuit; System overview - Refrigerant circuit
(vehicle-specific Workshop Manual) and ⇒ Electronic parts
catalogue
♦ 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.
♦ 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)
⇒ Electronic parts catalogue .

360 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

10.2.17 Capacities for Audi A6 (4G_ or 4X_ for

China ) 2011 ►, Audi A7 (4G_ or 4X_ for
China) 2011 ►, Audi A6 Hybrid (4G_)
2012 ►

Note

Also applies to Audi S and RS models.

Characteristics of refrigerant circuit:

• 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 2014, depending on the engine) ⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific Workshop Manual) and ⇒
Electronic parts catalogue (all vehicles except Audi A6 hybrid).
• On vehicles with a high-voltage system (Audi A6 Hybrid), elec‐
trically driven “Denso” air conditioner compressors ⇒ Heating,
air conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - Refrigerant circuit (vehicle-specific Workshop Manual)
and ⇒ Electronic parts catalogue .
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 A6 From 02.11 120 + / - 10 120 + / - 10 • “Denso” air conditioner
onwards compressor with oil
separator

Audi A7 From 10.10 120 + / - 10 120 + / - 10 • Air conditioner com‐

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”

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 361
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Note

♦ On certain versions for China the type designation 4X_ is used

instead of 4G_.
♦ 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 270 .
♦ At the start of production, all vehicles except the Audi A6 hybrid
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‐
tioning; Rep. gr. 87 ; Refrigerant circuit; System overview -
Refrigerant circuit (vehicle-specific Workshop Manual).
♦ At the start of production, the Audi A6 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.
♦ At the start of production, the Audi A6 hybrid was fitted with an
air conditioner compressor with a refrigerant oil quantity of
200 ccm. Shortly after the start of production, the 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 .
♦ As of Model Year 2014, air conditioner compressors are grad‐
ually being introduced for certain engines and versions which
are additionally fitted with an air conditioning system magnetic
clutch - N25- at the pulley (e.g. type “6 SES 14” or “6 SAS 14”)
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
System overview - Refrigerant circuit (vehicle-specific work‐
shop manual) and ⇒ Electronic parts catalogue .
♦ As of Model Year 2015, air conditioner compressors are grad‐
ually to 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. 87 ;
Refrigerant circuit; System overview - Refrigerant circuit (ve‐
hicle-specific workshop manual) and ⇒ Electronic parts cata‐
logue . On vehicles with such air conditioner compressors, the
quantity of refrigeration oil in the refrigerant circuit is 110 ccm
+20 / -10 ccm (the quantity of refrigeration 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 refrigeration oil capacity of 120 ccm remains valid for
such vehicles (if applicable, add 10 ccm of refrigeration oil after
flushing the refrigerant circuit and installing a new air condi‐
tioner compressor).

362 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

♦ 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 ;
Refrigerant circuit; System overview - refrigerant circuit (vehi‐
cle-specific Workshop Manual) and ⇒ Electronic parts cata‐
logue .
♦ 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. Attention is to be paid to these
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.
♦ 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.

10.2.18 Capacities for Audi V8 (4C_) ► 1994

Characteristics of refrigerant circuit:
• Restrictor (not coloured).
• Reservoir
• Air conditioner compressor from “Zexel / Valeo” ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - Refrigerant circuit (vehicle-specific Workshop Manual)
and ⇒ Electronic parts catalogue
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 V8 From 10.92 250 + 50 250 + 50
to 10.93

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 270 .
♦ 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).

10.2.19 Capacities for Audi A8 (4D_) 1994 ►

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 363
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 A8 From 05.94 onwards 250 + 50 250 + 50

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 270 .
♦ Exclusive use was made at the start of production of “Zexel /
Valeo” air conditioner compressors. As of Model Year 1996,
production was gradually switched to “Denso” air conditioner
compressors ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐
frigerant circuit; System overview - Refrigerant circuit (vehicle-
specific Workshop Manual) and ⇒ Electronic parts catalogue .
♦ 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).

10.2.20 Capacities for Audi A8 (4E_) 2003 ►

Characteristics of refrigerant circuit:
• Restrictor
• Reservoir
• “Denso” air conditioner compressor with air conditioner com‐
pressor regulating valve - N280- ⇒ Heating, air conditioning;
Rep. gr. 87 ; Refrigerant circuit; System overview - Refrigerant
circuit (vehicle-specific Workshop Manual) and ⇒ Electronic
parts catalogue
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 l All to notes below)
or 4.2 l (except
FSI)

• 6 and 12-cyl. From 10.02 200+/ - 10 200+/ - 10 Air conditioner compres‐

petrol engine to 01.04 sor type “6 SEU 14”, “7
SEU 16” or “7 SEU
• 6 and 8-cyl. 17” (refer to notes below)
diesel engine

• 6, 10 and 12- From 01.04 150 + / - 10 150+ / - 10 Air conditioner compres‐

cyl. petrol en‐ onwards sor type “6 SEU 14” or “7
gine SEU 17” (refer to notes
below)
• 6 and 8-cyl.
diesel engine
• 8-cyl. 4.2 l pet‐
rol engine (FSI
only)

364 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 270 .
♦ The Audi A8 is fitted with different air conditioner compressors
depending on the engine and production period.
♦ This air conditioner compressor is available as a replacement
part with different oil capacities, so it is important to pay at‐
tention to the exact part number ⇒ Heating, air conditioning;
Rep. gr. 87 ; Refrigerant circuit; System overview - Refrigerant
circuit (vehicle-specific Workshop Manual) and ⇒ Electronic
parts catalogue .
♦ 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 .
♦ 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. Note these oil quantities. Too
much oil in the circuit results in higher pressures and a reduced
cooling output of the system. Too little oil may lead to lubrica‐
tion 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.

10.2.21 Capacities for Audi A8 (4H_) 2010 ►,

Audi A8 hybrid (4H_) 2012 ►
Characteristics of refrigerant circuit:
• Expansion valve
• With one or two evaporator(s) depending on equipment
• Refrigerant line with internal heat exchanger
• Desiccant cartridge in receiver at condenser
• Mechanically driven “Denso” air conditioner compressor with
air conditioner compressor regulating valve - N280- ⇒ Heat‐
ing, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System
overview - Refrigerant circuit (vehicle-specific Workshop Man‐
ual) and ⇒ Electronic parts catalogue (all vehicles except Audi
A8 hybrid).
• On vehicles with a high-voltage system (Audi A8 Hybrid), elec‐
trically driven “Denso” air conditioner compressors ⇒ Heating,
air conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐
view - Refrigerant circuit (vehicle-specific Workshop Manual)
and ⇒ Electronic parts catalogue .

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 365
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Caution

Different refrigerant and refrigerant oil capacity for vehicles

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 ex‐ 03.10
cept 8- on‐
cyl. TDI wards
engine)
♦ Vehi‐ 130+/ - 10 ♦ 130+/ - 10 • One evap‐
cle 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+/ - 10 • One evap‐
cle orator
with
one
evap‐
orator

♦ Vehi‐ 180+/ - 10 • Two evap‐

cle orators
with (refer to
two notes be‐
evap‐ low)
ora‐
tors

366 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 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

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 367
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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, vehicles with two evaporators are
filled with the same amount of oil as vehicles with one evapo‐
rator. On account of the longer refrigerant lines and the second
evaporator, no greater quantity of refrigerant oil is currently
required in the refrigerant circuit on this vehicle. With this ve‐
hicle, the design of the refrigerant circuit means that only a
small proportion of the refrigerant oil passes into the refriger‐
ant lines to the second evaporator and into the second evap‐
orator during air conditioner operation. 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 vehicles 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 270 .
♦ For vehicles with an 8-cyl. TDI engine, the quantity of refrig‐
eration oil in the refrigerant circuit was increased as of vehicle
identification number 4H_ BN 018846 from 130 ccm to 180
ccm . Accordingly, the refrigerant capacity thus had to be re‐
duced 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 for
example after cleaning the refrigerant circuit, check the quan‐
tity of refrigerant oil in the refrigerant circuit and top up if
necessary, or add the correct quantity (e.g. at open pipes or
component connections or by way of the air conditioner serv‐
ice 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 270 .

368 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

♦ 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. Note these oil quantities. Too
much oil in the circuit results in higher pressures and a reduced
cooling output of the system. Too little oil may lead to lubrica‐
tion problems in the air conditioner compressor.
♦ 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.
♦ 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.
♦ At the start of production, all vehicles except the Audi A8 hybrid
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
circuit; System overview - Refrigerant circuit (vehicle-specific
Workshop Manual).
♦ At the start of production, the Audi A8 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.
♦ At the start of production, the Audi A8 hybrid was fitted with an
air conditioner compressor with a refrigerant oil quantity of
200 ccm. Shortly after the start of production, the 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 .

10.2.22 Capacities for Audi Q7 (4L_) 2006 ►

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 369
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 Q7 From
02.06
on‐
wards
♦ Vehi‐ 140, 150 or ♦ 140+/ - 10 • One evap‐
cle 160+ 15 / (air con‐ orator
with - 10 (de‐ ditioner
one • Air condi‐
pending on compres‐ tioner
evap‐ the air con‐ sor for ve‐
orator compres‐
ditioner hicle with sor type “6
compressor 6-cyl. TDI SEU 14”
fitted) 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 15 / compres‐
with - 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)

370 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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. On account
of the greater refrigerant line length and the second evapora‐
tor, vehicles 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 re‐
frigerant circuit, this quantity of refrigerant oil therefore has to
be added to the refrigerant circuit on vehicles with two evap‐
orators (e.g. poured into open pipes or component connec‐
tions). 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 270 .
♦ As replacement air conditioner compressors with different oil
capacities are available, it is important to observe the exact
part number ⇒ Electronic parts catalogue .
♦ The different oil quantities in the air conditioner compressor
may result from the design of the air conditioner compressor
(with or without oil separator at high-pressure connection) or,
in the case of identical air conditioner compressors, from the
design of the refrigerant circuit. Note these oil quantities. Too
much oil in the circuit results in higher pressures and a reduced
cooling output of the system. Too little oil may lead to lubrica‐
tion 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.

10.2.23 Capacities for Audi R8 (42_) 2008 ►

Characteristics of refrigerant circuit:
• Restrictor
• Reservoir
• Two series-connected condensers
• “Denso” air conditioner compressor with air conditioner com‐
pressor regulating valve - N280- ⇒ Heating, air conditioning;
Rep. gr. 87 ; Refrigerant circuit; System overview - Refrigerant
circuit (vehicle-specific Workshop Manual) and ⇒ Electronic
parts catalogue
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 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).

10. Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils 371
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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
From 11.12 200 + /- 10 200 + /- 10
onwards

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 270 .
♦ As replacement air conditioner compressors with different oil
capacities are available, it is important to observe the exact
part number ⇒ Electronic parts catalogue .
♦ 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‐
tronic parts catalogue and ⇒ Heating, air conditioning; Rep.
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
⇒ “10.1.21 Capacities for Audi R8 (42_) 2008 ►”, page 331 .
♦ 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 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.
♦ 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. Note these oil quantities. Too
much oil in the refrigerant 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
compressor. Therefore it is important to observe the specified
refrigerant oil quantities.

372 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

11 Test equipment and tools

⇒ “11.1 List of testers, tools and materials”, page 373
⇒ “11.2 Tools and materials available from regional sales centre
or importer”, page 375
⇒ “11.3 Commercially available tools and materials”, page 378
⇒ “11.4 Improvised tools”, page 379

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 373 .
♦ Commercially available tools and materials ⇒ page 374 .
♦ Improvised tools ⇒ page 375 .

11.1.1 Tools and materials available from regional sales centre or importer
Overview Page
Air conditioner service station with flushing attachment for currently avail‐ See Figure and ⇒ Electronic parts
able air conditioner service stations ⇒ Electronic parts catalogue (Tools; catalogue
Workshop 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 purging 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)
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
logue (Tools; Workshop equipment/tools; Air conditioning/heating) catalogue

11. Test equipment and tools 373

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Overview Page
Adapter set with service connection V.A.G 1786 ⇒ Electronic parts cata‐ See Figure and ⇒ Electronic parts
logue (Tools; Workshop equipment/tools; Air conditioning/heating) catalogue
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
Charging 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 pipes Not illustrated
Valve opener for charging hoses Not illustrated
Connecting nipple for conical seal 5/8"-18 UNF Not illustrated
Compressed-air gun with rubber end piece Not illustrated
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
Hand shut-off valve 5/8"-18 UNF Not illustrated
Recycling container for refrigerant R134a Not illustrated
Digital thermometer Not illustrated

374 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Overview Page
Protective gloves Not illustrated
Safety goggles Not illustrated
Refrigerant R134a with cylinder (capacity as required) Not illustrated

11.1.3 Improvised tools

Overview Page
Charging hose with connection to workshop compressed air system 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 at the latest at
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‐
shop equipment/tools; Air conditioning/heating).
♦ 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 attachment ⇒ Electronic parts cata‐
logue (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.

11. Test equipment and tools 375

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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 116 or blow out with compressed air and nitrogen
⇒ page 108 .
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

376 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Adapter
A - 5/8"-18 UNF thread for conical seal
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
A - 5/8"-18 UNF thread for conical seal
B - Internal thread with valve opener
♦ M 10 x 1.25 V.A.G 1785/9 (for connections with valve on high-
pressure side)
♦ M 12 x 1.5 V.A.G 1785/10 (for connections on low-pressure
side)

Note

♦ A Schrader valve is screwed into connection -A-.

♦ A valve opener must be installed in the charging hose con‐
nection.
♦ 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 - Charging hose with union nut 5/8"-18 UNF(short version)
C - Adapter with service connection - V.A.G 1786/2-

Note

♦ For connections with a large valve core (standard on “Zexel /

Valeo” compressors, gradual change to small valve core as of
10.94), use adapter V.A.G 1785/10 (remove valve from adapt‐
er V.A.G 1785/10 or install valve opener in charging hose -B-).
♦ 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).

11. Test equipment and tools 377

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

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

Charging hoses
5/8"-18 UNF thread

Note

♦ Use differently coloured charging 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

378 Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 11.2014

Valve caps with spare seals (for 5/8"-18 UNF thread)

Seals can also be used for charging 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, nominal size 16 mm
♦ Low-pressure side, nominal size 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 ID)
B - Connection for workshop compressed-air system ** (always
use filter)

11. Test equipment and tools 379

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