Air Conditioner With Refrigerant R134a

Service
Workshop Manual
Audi 100 1991 ➤ , Audi 80 1992 ➤ ,
Audi A1 2011 ➤ , Audi A2 2001 ➤ ,
Audi A3 1997 ➤ , Audi A3 2004 ➤ ,
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 A7 Sportback 2011 ➤ ,
Audi A8 1994 ➤ , Audi A8 2003 ➤ ,
Audi A8 2010 ➤ , Audi Cabriolet 1991 ➤ ,
Audi Q5 2008 ➤ , Audi Q7 2007 ➤ ,
Audi R8 2007 ➤ , Audi TT 1999 ➤ ,
Audi TT 2007 ➤
Air conditioner with refrigerant R134a
Edition 06.2010
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
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt A0053300220

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...
Air conditioner with refrigerant R134a - Edition 06.2010
Contents
87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 General information on air conditioning systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Other reference material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Principles of air conditioning systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Properties of refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.6 Refrigerant oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.7 How air conditioning works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.8 General work safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.9 Product properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.10 Handling refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.11 Handling pressure vessels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.12 Safety regulations for working with extraction and charging systems . . . . . . . . . . . . . . . . 12
1.13 Safety measures for working on vehicles with air conditioning system and for handling
refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.14 Basic rules for working on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.15 Before using air conditioner after system has been re-charged . . . . . . . . . . . . . . . . . . . . . . 15
2 General information on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1 Components of refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2 Arrangement of the refrigerant circuit components and their influence on the high and low-
pressure ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3 Design of refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.4 Connections for quick-release coupling in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . 26
2.5 Switches and senders in refrigerant circuit and related connections . . . . . . . . . . . . . . . . 28
2.6 Electrical components not installed in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.7 Pressures and temperatures in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.8 Test and measurement operations which can be performed with a pressure gauge . . . . 37
2.9 Air conditioner service and recycling units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.10 Repair notes for refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3 Laws and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.1 Laws and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4 Refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.1 Important repair notes for air conditioning systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.2 Converting refrigerant circuits from refrigerant R12 to refrigerant R134a . . . . . . . . . . . . . . 45
4.3 Working with the air conditioner service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.4 Blowing out refrigerant circuit with compressed air and nitrogen . . . . . . . . . . . . . . . . . . . . 55
4.5 Flushing (cleaning) refrigerant circuit with refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . 59
4.6 Tracing leaks in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5 Problems with refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.1 Possible complaints about refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6 Connecting air conditioner service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6.1 Connecting air conditioner service station on vehicles with a connection on the low and high-
pressure end of the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6.2 Connecting air conditioner service station on vehicles with no connection on the low-pressure
end of the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7 Checking pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.1 Checking pressures in refrigerant circuit with air conditioner service station (with ignition
switched off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.2 Checking pressures on vehicles with a restrictor and reservoir (with internally regulated air
conditioner compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
7.3 Checking pressures on vehicles with an expansion valve and receiver (with internally
regulated air conditioner compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Contents i
7.4 Checking pressures on vehicles with restrictor, reservoir and air conditioner compressor
regulating valve N280 (with externally regulated air conditioner compressor) . . . . . . . . . . 118
7.5 Checking pressures on vehicles with expansion valve, receiver and air conditioner
compressor regulating valve N280 (with externally regulated air conditioner compressor)
........................................................................ 126
8 Renewing components of refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
8.1 Renewing components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
9 Capacities for refrigerant R134a, refrigerant oil and approved refrigerant oils . . . . . . . . . . 144
9.1 Capacities for refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
9.2 Approved refrigerant oils and refrigerant oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
10 Test equipment and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
10.1 List of testers, tools and materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
10.2 Tools and materials available from regional sales centre or importer . . . . . . . . . . . . . . . . 191
10.3 Commercially available tools and materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
10.4 Improvised tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
ii Contents
87 – Air conditioning system

1 General information on air condition‐
ing systems
♦ Introduction ⇒ page 1
♦ Other reference material ⇒ page 1
♦ Principles of air conditioning systems ⇒ page 2
♦ Refrigerant R134a ⇒ page 4
♦ Properties of refrigerant R134a ⇒ page 5
♦ Refrigerant oil ⇒ page 7
♦ How air conditioning works ⇒ page 8
♦ General work safety ⇒ page 10
♦ Product properties ⇒ page 10
♦ Handling refrigerant ⇒ page 10
♦ Handling pressure vessels ⇒ page 11
♦ Safety regulations for working with extraction and charging
systems ⇒ page 12
♦ Safety measures for working on vehicles with air conditioning
system and for handling refrigerant R134a ⇒ page 13
♦ Basic rules for working on refrigerant circuit ⇒ page 14
♦ Before using air conditioner after system has been re-charged
⇒ page 15
1.1 Introduction
This manual is intended to provide foremen and mechanics with
the basic knowledge needed to ensure reliable and successful
repairs.
Note
This requires careful study of the manual, coupled with suitable

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

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

♦ Workshop manual for model-specific servicing work ⇒ Heat‐
ing, air conditioning; Rep. gr. 87 or ⇒ Air conditioning; Rep.
gr. 87 (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
1. General information on air conditioning systems 1

♦ List of special tools and workshop equipment required for

servicing air conditioning systems ⇒ Workshop equipment
catalogue
♦ Service Organisation Handbook, Vol. „1“ „Additional equip‐
ment“ ⇒ Audi ServiceNet, Handbooks
♦ Air conditioner with refrigerant R12 Workshop Manual (for ve‐
hicles manufactured up to model year 1993; this Workshop
Manual is available in hardcopy form only)
1.3 Principles of air conditioning systems

♦ Physical principles ⇒ page 2
♦ Pressure and boiling point ⇒ page 2
♦ Vapour pressure table for refrigerant R134a ⇒ page 3
♦ Properties of refrigerant R134a ⇒ page 5
1.3.1 Physical principles

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

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

The boiling point given in tables for a liquid is always referenced
to an atmospheric pressure of 1 bar. If the pressure acting on a
liquid changes, its boiling point also changes.
2 Rep. gr.87 - Air conditioning system

Note
Pressure may be given in various units: 1 MPa (megapascal) cor‐

responds to 10 bar gauge pressure or 145 psi; 1 bar absolute
pressure corresponds to 0 bar gauge pressure, which is roughly
equivalent to atmospheric pressure.
For example, the lower the pressure, the lower the temperature
at which water boils.
The vapour pressure curves for water and refrigerant R134a show
for example that, at constant pressure, reducing the temperature
changes vapour to liquid (in the condenser) or that, for instance,
reducing pressure causes the refrigerant to change from the liquid
to the vapour state (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
1.3.3 Vapour pressure table for refrigerant

R134a
The vapour pressure table for every refrigerant is published in
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 known characteristic vapour pressure table for every
refrigerant, the type of refrigerant can be identified by way of
pressure and temperature measurement.

Note
♦ At absolute pressure, „0 bar“ corresponds to an absolute vac‐

uum. Normal atmospheric pressure corresponds to „1 bar“
absolute pressure. On the scales of most pressure gauges, „0
bar“ corresponds to an absolute pressure of 1 bar (this is in‐
dicated by the value „-1 bar“ below „0“).
♦ Pressure may be given in various units: 1 MPa (megapascal)
corresponds to 10 bar gauge pressure or 145 psi; 1 bar ab‐
solute pressure corresponds to 0 bar gauge pressure, which
is roughly equivalent to atmospheric pressure.
Temperature in °C Pressure in bar (gauge pres‐

sure), R134a
-45 -0,61
-40 -0,49
-35 -0,34
-30 -0,16
-25 0,06
-20 0,32
-15 0,63
-10 1,00
-5 1,43
0 1,92
5 2,49
10 3,13
15 3,90
20 4,70
25 5,63
30 6,70
35 7,83
40 9,10
45 10,54
50 12,11
55 13,83
60 15,72
65 17,79
70 20,05
75 22,52
80 25,21
85 28,14
90 31,34
1.4 Refrigerant R134a

Vehicle air conditioning systems make use of the vaporisation and
condensation process. These systems employ a substance with
a low boiling point, referred to as refrigerant.
The refrigerant used is tetrafluoroethane R134a, which boils at
-26.5°C at a vapour pressure of „1 bar“.
♦ Physical properties of refrigerant R134a ⇒ page 5

♦ Critical point ⇒ page 5

♦ Environmental aspects of refrigerant R134a ⇒ page 5
1.4.1 Physical properties of refrigerant R134a

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

The critical point (critical temperature and critical pressure) is that
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 3 „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.
1.4.3 Environmental aspects of refrigerant

R134a
♦ R134a is a fluorocarbon and contains no chlorine.
♦ R134a has a shorter atmospheric lifespan than refrigerant
R12.
♦ R134a does not damage the ozone layer, the ozone depletion
potential is zero.
♦ The global warming potential (GWP) of R134a is 1300 (the
GWP of carbon dioxide = 1).
♦ The global warming effect of R134a is ten times less than that
of refrigerant R12.
1.5 Properties of refrigerant R134a

♦ Trade names and designations ⇒ page 6
♦ Colour ⇒ page 6
♦ Vapour pressure ⇒ page 6
♦ Physical properties of R134a ⇒ page 6
♦ Reaction with metals ⇒ page 6
♦ Critical temperature/critical pressure ⇒ page 6
♦ Water content ⇒ page 7
♦ Combustibility ⇒ page 7

♦ Charge factor ⇒ page 7

♦ Tracing leaks ⇒ page 7
1.5.1 Trade names and designations

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

♦ Of the wide range of refrigerants available, this is the only one
which may be used for vehicles. The designations Frigen and
Freon are trade names. They also apply to refrigerants which
should not be used in vehicles.
1.5.2 Colour
Like water, refrigerants are colourless in both vapour and liquid
form. Gas is invisible. Only the boundary layer between gas and
liquid is visible (liquid level in indicator tube of charging cylinder
or bubbles in 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.
1.5.3 Vapour pressure

In a partially filled, closed vessel, the quantity of refrigerant evap‐
orating from the surface equals the quantity returning to the liquid
state as vapour particles condense. This state of equilibrium oc‐
curs under the influence of pressure and is often called vapour
pressure. Vapour pressure is dependent on temperature
⇒ page 3 „Vapour pressure table“.
1.5.4 Physical properties of R134a

As the vapour pressure curves of R134a and other refrigerants
are sometimes very similar, unequivocal identification cannot be
made simply on the basis of pressure.
When using R134a, the air conditioner compressor is lubricated
by means of special synthetic refrigerant oils, e.g. PAG oils (pol‐
yalkylene glycol oils).
1.5.5 Reaction with metals

In its pure state, refrigerant R134a is chemically stable and does
not corrode iron or aluminium.
However, contamination of the refrigerant, e.g. with chlorine com‐
pounds, leads to the corrosion of certain metals and plastics. This
can result in blockage, leaks or deposits at the air conditioner
compressor piston.
1.5.6 Critical temperature/critical pressure

The refrigerant R134a remains chemically stable up to a gas
pressure of 39.5 bar (corresponding to a temperature of 101 °C).
Above this temperature, the refrigerant decomposes (refer to
"Combustibility").

1.5.7 Water content

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

A vessel 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
vessels being overfilled, regulations governing the storage of
compressed gases specify the number of kilograms of refrigerant
with which a vessel may be filled per litre of internal vessel vol‐
ume. The maximum permissible capacity is calculated by multi‐
plying this "charge factor" by the internal volume of the vessel.
The figure for the refrigerant used in motor vehicles is 1.15 kg/
litre.
1.5.10 Tracing leaks

External damage, for example, can cause a leak in the refrigerant
circuit. The small quantity of refrigerant escaping from minor leaks
can be detected for example using an electronic leak detector or
by introducing a leak detection additive into the refrigerant circuit.
Electronic leak detectors are capable of registering leaks with re‐
frigerant losses of less than 5 g per year.
Note
Use must be made for the various refrigerants of leak detectors

designed for the composition of the refrigerant concerned. For
example, a leak detector for R12 refrigerant is not appropriate for
R134a, as R134a refrigerant has no chlorine atoms and the leak
detector therefore does not respond.
1.6 Refrigerant oil

Refrigerant oil mixes with the refrigerant (about 20 - 40 %, de‐
pending on compressor type and amount 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
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; exclusive use is therefore to be made of au‐
thorised oils.
⇒ Electronic parts catalogue
Type of oil for R134a in motor vehicles: PAG. (polyalkylene glycol)
Note
♦ Do not store refrigerant oils in open containers as they are

extremely hygroscopic (water-absorbing).
♦ Always keep oil containers sealed.
♦ Do not re-use old refrigerant oil. It must be disposed of as used
oil of unknown origin ⇒ Audi-ServiceNet, HSO Environmental
Protection .
♦ Ester-based oils are only intended for use with large systems
(not for motor vehicle air conditioners).
♦ Properties of refrigerant oil ⇒ page 8
1.6.1 Properties of refrigerant oil

The most important properties are a high degree of solubility with
refrigerant, good lubricity, absence of acid and minimal water
content. It is therefore only permissible to use certain specified
oils. For a list of approved refrigerant oils and capacities, refer to
⇒ page 164 .
PAG oils, which are appropriate 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 promote the ageing of refrigerant
oil, causing it to become dark, viscous and corrosive towards
metals.
Note
♦ On account of its chemical properties, the refrigerant oil is not

to be disposed of together with engine or gear oil. Refrigerant
oil must be disposed of as used oil of unknown origin ⇒ Audi-
ServiceNet, HSO Environmental Protection .
♦ Only oil approved for the air conditioner compressor is to be
used for refrigerant circuits containing refrigerant R134a ⇒
Electronic parts catalogue and capacities ⇒ page 164 .
1.7 How air conditioning works

The temperature in the passenger compartment depends on the
amount of heat radiated into the vehicle through the windows and
conducted by the metal parts of the body. In hot weather some of
the heat must be pumped off to achieve a more comfortable tem‐
perature for the occupants.
As heat spreads into cooler areas, the passenger compartment
is fitted with a unit for generating low temperatures in which re‐
frigerant is constantly evaporated. The heat required for this is
extracted from the air flowing through the evaporator.
After absorbing heat, the refrigerant is pumped off through the air
conditioner compressor. The work of compression of the air con‐

ditioner compressor increases the heat content and temperature

of the refrigerant. Its temperature is then substantially higher than
that of the surrounding 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 is re-
used, 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.
♦ Comfort of vehicle occupants ⇒ page 9
♦ Environmental aspects ⇒ page 9
1.7.1 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. Comfort can of course also be en‐
hanced by opening windows/the sun roof or increasing the air
output. Such a course of action is however associated with certain
drawbacks for the occupants of the vehicle, e.g. more noise,
draughts, exhaust fumes and unfiltered pollen (unpleasant for al‐
lergy sufferers).
Climate control together with a good heating and ventilation sys‐
tem concept can create a sense of wellbeing and comfort by
regulating the temperature, humidity and air circulation in the
passenger compartment to suit ambient conditions, with the ve‐
hicle both stationary and moving.
Other important advantages of air conditioning:
♦ Purification of the air supplied to the passenger compartment
(dust and pollen, for example, are washed out by the moist fins
of the evaporator and removed with the condensate).
♦ Temperatures in a mid-size car (example: after short travelling
time, ambient temperature 30 °C in the shade and vehicle ex‐
posed to sunlight).
With air conditioning Without air condi‐
tioning
At head height 23 °C 42 °C
At chest level 24 °C 40 °C
In footwell 30 °C 35 °C
1.7.2 Environmental aspects

Since about 1992, the air conditioning systems of newly manu‐
factured cars have been successively changed to refrigerant
R134a. This refrigerant contains no chlorine and therefore does
not deplete the ozone layer.
Up until roughly 1992, refrigerant R12 was used for air condition‐
ing systems. Due to its chlorine atoms, this CFC had a high ozone
depletion potential as well as potential for intensifying the green‐
house effect.
Conversion programmes are available for old existing systems
filled with the ozone-depleting substance R12 ⇒ Workshop Man‐
ual for air conditioners with refrigerant R12 (this Workshop Man‐
ual is available in hardcopy form only).

For environmental reasons, refrigerants must not be released into

the atmosphere ⇒ page 40 (see the relevant environmental leg‐
islation).
1.8 General work safety

♦ In accordance with regulations of the German industrial liabil‐
ity insurance association, VBG 20, (other regulations may
apply in other countries)
♦ Heed the workplace-specific instructions ⇒ Audi-ServiceNet,
HSO Environmental Protection , which are to be displayed at
refrigerant workplaces.
1.9 Product properties

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

If refrigerant vessels are opened, the contents may escape in liq‐
uid or vapour form. The higher the pressure in the vessel, the
more vigourous 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
♦ Do not open vessels containing refrigerant.
Wear safety goggles

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

Smoking is absolutely prohibited

A burning cigarette can cause refrigerant to decompose. The re‐
sultant substances are toxic and must not be inhaled.
Welding and soldering on refrigeration systems
Before performing welding, brazing or soldering work on vehicles
in the vicinity of air conditioning system components, extract re‐
frigerant and remove any remaining refrigerant by blowing out
with nitrogen.
The products of decomposition of the refrigerant arising from the
effect of heat are not only toxic, but also highly corrosive and can
therefore damage pipes and sections of the system. The principal
substance is hydrogen fluoride.
Pungent odour
A pungent odour indicates that the products of decomposition
mentioned above have already formed. Avoid inhaling these sub‐
stances under all circumstances, as otherwise the airways, lungs
and other organs 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.
♦ Handling pressure vessels ⇒ page 11
1.11 Handling pressure vessels

Secure vessels to prevent them falling over.
Secure upright cylinders to stop them falling over and cylinders
lying flat to stop them rolling away.
Pressure vessels must never be thrown.
If dropped, the vessels could be so severely deformed that they
rupture. The refrigerant evaporates immediately, liberating con‐
siderable force. Flying fragments of cylinders can cause severe
injuries.
To protect the valves, cylinders may only be transported with the
protective cap screwed on.
Valves may break off if cylinders are not properly transported.
Never store in the vicinity of radiators.
High temperatures may occur in such areas. High temperatures
are also accompanied by high pressures and the maximum per‐
missible vessel pressure may be exceeded.
Never heat to above 50 °C
To avoid possible risk, pressure vessel regulations specify that
vessels are not to be heated to in excess of 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 causes steel containers to rust. This
weakens the vessel walls. In addition, any rust particles which
enter refrigeration systems from storage vessels will cause mal‐
functioning.
1.12 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, ensure that the process has been completed
so that no refrigerant can escape into the atmosphere.
• 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.
• Entrained oil from the air conditioning system drawn off by the
suction unit into the measurement vessel supplied is subse‐
quently to be transferred to a sealable container, as it contains
a small quantity of refrigerant which must not be released into
the environment.
• Following shutdown, the air conditioner service station must
be secured to stop it rolling away.

1.13 Safety measures for working on vehi‐

cles with air conditioning system and for
handling refrigerant R134a
WARNING
♦ It is advisable to keep an eye bath to hand.

♦ 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.
♦ The doctor must be informed that the frostbite was caused
by refrigerant R134a. Should refrigerant come into contact
with other parts of the body despite compliance with the
safety regulations, these must likewise be rinsed immedi‐
ately for approximately 15 minutes with cold water.
♦ 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.
• Welding, brazing and soldering work must not be performed

on components of air conditioning system when charged. This
also applies to vehicle welding and soldering work if there is a
danger of air conditioner components becoming hot. When
performing paintwork repairs, the temperature in the drying
booth or preheating zone must not exceed 80 °C.
Reason:
Exposure to heat gives rise to considerable pressure in the sys‐
tem, which could cause the pressure relief valve to open.
Remedy:
– Discharge refrigerant circuit using air conditioner service sta‐
tion.
Note
Damaged or leaking components of the air conditioning system

are not to be repaired by welding or soldering. They must always
be replaced.
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 5 .
Refrigerant should never be poured into systems or vessels con‐
taining any air.
Remedy:
– Evacuate systems and containers before charging with refrig‐
erant.

1.14 Basic rules for working on refrigerant cir‐

cuit
♦ General notes ⇒ page 14
♦ Cleaning refrigerant circuit ⇒ page 14 .
♦ Additionally for vehicles with air conditioner compressor with
no magnetic clutch (with air conditioner compressor regulating
valve -N280- ) ⇒ page 15
♦ O-rings ⇒ page 15
1.14.1 General notes

• Heed the workplace-specific instructions ⇒ 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 assemblies and hoses to prevent
the ingress of moisture and dirt.
• Use only tools and materials intended for refrigerant R134a.
• Seal opened refrigerant oil containers to protect against mois‐
ture.
Note
♦ After completing service work, screw sealing caps (with seals)

onto all connections with valves and service connections.
♦ Before starting up the air conditioning system, heed the vehi‐
cle-specific capacities ⇒ page 144 .
♦ Do not top up refrigerant in circuit; discharge existing refriger‐
ant and re-charge system.
1.14.2 Cleaning refrigerant circuit

The refrigerant circuit must be flushed out with refrigerant R134a
⇒ page 59 (or blown out with compressed air and nitrogen
⇒ page 55 ) in the following cases:
– If moisture or dirt has ingressed into the refrigerant circuit (e.g.
following an accident).
– If the refrigerant oil is dark and viscous.
– If there is too much refrigerant oil in the refrigerant circuit after
compressor replacement.
– If the air conditioner compressor has to be replaced on ac‐
count of „internal“ damage (e.g. noise or no output).

Note
When blowing out components with compressed air and nitrogen,

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

tioner compressor with no magnetic
clutch (with air conditioner compressor
regulating valve -N280- )
• The engine is only to be started following complete assembly
of the refrigerant circuit (constant air conditioner compressor
operation).
• If the engine has to be operated with the refrigerant circuit
empty, only do so for as long as absolutely essential and avoid
high engine speeds.
1.14.4 O-rings
♦ Make exclusive use of seals which are resistant to refrigerant
R134a and the related refrigerant oils. Colour coding of O-ring
seals is no longer employed. Black and coloured O-rings are
used.
♦ Pay attention to the correct inside diameter of the seals used
⇒ Electronic parts catalogue , ⇒ Heating, air conditioning;
Rep. gr. 87 and / or ⇒ Air conditioning; Rep. gr. 87 (vehicle-
specific workshop manual).
♦ Seals may only be used once.
♦ Before fitting, moisten seals slightly with refrigerant oil (PAG
oil).
1.15 Before using air conditioner after system

has been re-charged
– Give the air conditioner compressor approx. 10 turns by hand
by way of the magnetic clutch plate or the pulley.
– Start the engine with the air conditioning system switched off
( air conditioning system magnetic clutch -N25- and air condi‐
tioner compressor regulating valve -N280- are not actuated).
– Switch on the air conditioner compressor once the idling speed
has stabilised and run it for at least 10 minutes at idle in the
maximum cooling output setting.

2 General information on refrigerant

circuit
♦ Components of refrigerant circuit ⇒ page 16
♦ Arrangement of the refrigerant circuit components and their
influence on the high and low-pressure ends ⇒ page 16
♦ Design of refrigerant circuit ⇒ page 25
♦ Connections for quick-release coupling in refrigerant circuit
⇒ page 26
♦ Switches and senders in refrigerant circuit and related con‐
nections ⇒ page 28
♦ Electrical components not fitted in the refrigerant circuit
⇒ page 32 .
♦ Pressures and temperatures in refrigerant circuit
⇒ page 33
♦ Test and measurement operations which can be performed
with a pressure gauge ⇒ page 37
♦ Air conditioner service and recycling units ⇒ page 38
♦ Repair notes for refrigerant circuit ⇒ page 39
2.1 Components of refrigerant circuit

• All components of the refrigerant circuit submitted for quality
observation are always to be sealed (use the original sealing
caps of the replacement part).
• Renew damaged or leaking components of refrigerant circuit
⇒ page 136 .
Note
The following replacement parts (air conditioner compressor, res‐

ervoir, evaporator and condenser) have so far been filled with
nitrogen gas. This charge is being gradually discontinued. Con‐
sequently, no or only very slight pressure equalisation is percep‐
tible on unscrewing the sealing plugs from the replacement part.
2.2 Arrangement of the refrigerant circuit

components and their influence on the
high and low-pressure ends
High-pressure end: 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‐
tive, the system is blocked or in the event of moisture in the
refrigerant circuit (icing-up of restrictor or expansion valve).
Low-pressure end: Evaporator, evaporator temperature sensor
and air conditioner compressor to separate the high and low-
pressure gas ends.
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.

♦ Air conditioner compressor ⇒ page 18

♦ Condenser ⇒ page 19
♦ Evaporator ⇒ page 19
♦ Reservoir ⇒ page 19
♦ Restrictor ⇒ page 20
♦ Receiver ⇒ page 21
♦ Expansion valve ⇒ page 22
♦ Refrigerant line with internal heat exchanger ⇒ page 22
♦ Quick-release couplings on refrigerant line ⇒ page 23
♦ O-rings ⇒ page 24
♦ Pipes and hoses of refrigerant circuit ⇒ page 24
♦ Pressure relief valve ⇒ page 25
2. General information on refrigerant circuit 17

2.2.1 Air conditioner compressor

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 attached to the air conditioner com‐
pressor provides the power link between the pulley and the com‐
pressor crankshaft when the air conditioning system is switched
on.
Air conditioner compressor with no magnetic clutch:
An overload safeguard attached to the pulley or fitted in the drive
unit of the air conditioner compressor is triggered if the air condi‐
tioner compressor is not running smoothly in order to protect the
belt drive against overload.
The air conditioner compressor draws in refrigerant gas from the
evaporator, compresses it and conveys it to the condenser.
Note
♦ The air conditioner compressor contains refrigerant oil which

mixes with refrigerant R134a at all temperatures.
♦ The 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).
♦ A regulating valve is actuated externally on air conditioner
compressors with no 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 switched
to internal lubrication by way of a valve.
♦ Depending on the version of the air conditioner compressor,
the high-pressure end 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 end decreases (the expansion valve is cold and
the pressure on the low-pressure end increases rapidly after
switch-off, the expansion valve closes and the refrigerant can
only flow slowly to the low-pressure end). If the air conditioner
compressor is switched on, the pressure on the low-pressure
end decreases, the expansion valve opens and the refrigerant
can flow to the low-pressure end.

2.2.2 Condenser
The condenser dissipates heat from the compressed refrigerant
gas to the surrounding air.
During 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 installed in (integrated into)
the condenser ⇒ Heating, air conditioning; Rep. gr. 87 or ⇒ Air
conditioning; Rep. gr. 87 (vehicle-specific workshop manual) and
⇒ Electronic parts catalogue .
2.2.3 Evaporator
The liquid refrigerant evaporates in the coiled pipes of the evap‐
orator. 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 to‐
gether 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 such that only gaseous
refrigerant emerges at the evaporator outlet.
2.2.4 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 hole 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 replace‐
ment is stipulated due to a specific complaint ⇒ page 136 .
♦ 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).

2.2.5 Restrictor
The restrictor creates a constriction. This constriction restricts the
flow, thus separating the refrigerant circuit into a high and low-
pressure end. 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. A strainer is provided
upstream of the constriction to trap dirt. The strainer downstream
of the constriction is designed to atomise the refrigerant before it
enters the evaporator.
Note
♦ Arrow -A- on restrictor faces evaporator.

♦ Always replace after opening the circuit.
♦ Different versions exist; heed the applicable notes in the var‐
ious service information booklets ⇒ Heating, air conditioning;
Rep. gr. 87 or ⇒ Air conditioning; Rep. gr. 87 (vehicle-specific
workshop manual) and ⇒ Electronic parts catalogue .

2.2.6 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 replace‐
ment is stipulated due to a specific complaint ⇒ page 136 .
♦ 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 installed in (inte‐
grated into) the condenser ⇒ Heating, air conditioning; Rep.
gr. 87 or ⇒ Air conditioning; Rep. gr. 87 (vehicle-specific
♦ The procedure for dealing with problems differs depending on
the version of the receiver / dryer cartridge. If, for example, the
receiver is attached to the condenser, it can be replaced to‐
gether with the dryer cartridge. If, for example, the receiver is
integrated into the condenser, it is usually possible to replace
the dryer cartridge and any additional filter element separately.
If the receiver is integrated into the condenser and it is not
possible to replace the receiver/dryer cartridge separately, it
may be necessary to replace the entire condenser ⇒ Heating,
air conditioning; Rep. gr. 87 or ⇒ Air conditioning; Rep. gr.
87 (vehicle-specific workshop manual) and ⇒ Electronic parts
catalogue .
♦ Depending on the design of the refrigerant circuit, the desic‐
cant bag (dryer cartridge) may also be installed in the con‐
denser ⇒ Heating, air conditioning; Rep. gr. 87 or ⇒ Air
conditioning; Rep. gr. 87 (vehicle-specific workshop manual)
and ⇒ Electronic parts catalogue .

2.2.7 Expansion valve

The expansion valve atomises the refrigerant flowing in and con‐
trols the flow rate in line with the quantity of heat transferred such
that it does not become gaseous before reaching the evaporator
outlet.
Note
♦ Pay attention to the correct part number on replacing the ex‐

pansion valve ⇒ Electronic parts catalogue .
♦ Different characteristic curves matched to the appropriate cir‐
cuit ⇒ Heating, air conditioning; Rep. gr. 87 or ⇒ Air condi‐
tioning; Rep. gr. 87 (vehicle-specific workshop manual) and
2.2.8 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 pipe with an internal heat ex‐

changer as fitted for example on the Audi A4 2008 > and the Audi
A5 Coupé 2008 > ⇒ Air conditioning; Rep. gr. 87 (vehicle-specific
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 end 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
end of the refrigerant circuit).

2.2.9 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 pipe with an internal heat exchanger as fitted for
example on the Audi A4 2008 > and the Audi A5 Coupé 2008
> ⇒ Air conditioning; Rep. gr. 87 (vehicle-specific workshop
manual).
♦ Removal of the refrigerant line -D- involves opening the re‐
taining ring -A- with the air conditioner line release tool -
T40149/- for example ⇒ Air conditioning; Rep. gr. 87 (vehicle-
♦ Following removal of the applicable refrigerant pipe, the quick-
release couplings -B- and -G- are to be replaced together with
the corresponding support ring -E- or -H- and the correspond‐
ing O-ring -F- or -J- ⇒ Air conditioning; Rep. gr. 87 (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 pipe with an internal heat exchanger
D - Refrigerant line ( „high-pressure side“)
E - Support ring ( „high-pressure side“)
F - O-ring ( „high-pressure side“)
G - Quick-release coupling with retaining ring ( „low-pressure
side“)
H - Support ring ( „low-pressure side“)
J - O-ring ( „low-pressure side“)

Note
♦
♦ There are different versions -A- and -D- of the quick-release
couplings. With both versions of these quick-release cou‐
plings, the refrigerant lines -C- can be released in the identical
manner using the air conditioner 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 -A- to be gradually introduced
as of Model Year 2010, the refrigerant line -C- is fitted in the
same manner as for the quick-release coupling -A-. If, with this
version, the refrigerant line -C- is pulled in arrow direction fol‐
lowing assembly, the snap ring -E- emerges from the quick-
release coupling -D- to show that the retaining ring -F- and the
refrigerant line -C- are fully locked. The snap ring -E- is then
to be detached from the refrigerant line -C-.
2.2.10 O-rings
These rings seal the joints between the individual components of
the refrigerant circuit.
Only O-rings resistant to R134a refrigerant and the related refrig‐
erant oils are to be used. This is guaranteed if genuine replace‐
ment parts are used.
O-rings:
– Use only once.
– Observe correct diameters -a- and -b-.
– Moisten with refrigerant oil before fitting ⇒ Heating, air condi‐
tioning; Rep. gr. 87 or ⇒ Air conditioning; Rep. gr. 87 (vehicle-
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 or ⇒ Air conditioning; Rep. gr. 87 (vehicle-specific work‐
shop manual).
2.2.11 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 held together by bolted joints or by way
of special connectors.
Note
Observe specified torques for bolted joints and use the specified
release tools for connectors.

2.2.12 Pressure relief valve

The pressure relief valve is attached to the air conditioner com‐
pressor or 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.
Certain versions feature a transparent plastic disc which breaks
off as soon as the valve responds.
2.3 Design of refrigerant circuit

♦ Refrigerant circuit with expansion valve and evaporator
⇒ page 25
♦ Refrigerant circuit with restrictor and reservoir ⇒ page 25
2.3.1 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.
2.3.2 Refrigerant circuit with restrictor and

reservoir
1- Air conditioner compressor
2- Condenser
3- Restrictor
4- Evaporator
5- Reservoir
Note

2.4 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.
• Discharge refrigerant circuit before removing valves or valve
cores.
• Always screw on sealing caps.
Layout in vehicle ⇒ Heating, air conditioning; Rep. gr. 87 or ⇒
Air conditioning; Rep. gr. 87 (vehicle-specific Workshop Manual).
♦ Connections with Schrader valve (needle valve) ⇒ page 26
♦ Connections with primary sealing valve (ball valve)
⇒ page 27
2.4.1 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 and the tightening
torques therefore also differ. The tightening torque for a valve
insert -B- with a VG5 thread (5.2 x 0.7 mm, tyre valve) is
0.4 Nm +- 0.1 Nm. For a valve insert with an M6 x 0.75 mm
thread, the tightening torque is 0.9 Nm +- 0.1 Nm and for a
valve insert with an M8 x 1.0 mm thread it is 2.0 Nm +- 0.2 Nm.
♦ There are different versions of these valves, the valve cores
and the corresponding sealing caps. Attention is to be paid to
the correct version of the valve core and correct assignment
of the sealing caps ⇒ Electronic parts catalogue .

2.4.2 Connections with primary sealing valve

(ball valve)
WARNING
Before unscrewing connection, connect 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- Sealing 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. The tightening torque for the valves -3- used at present
with an M12 x 1.5 mm external thread is 9 Nm +- 1 Nm.
♦ There are different versions of these valves and the corre‐
sponding sealing caps. Attention is to be paid to the correct
version of the valve and correct assignment of the sealing cap

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- Sealing 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
example.
♦ There are different versions of these valves (with internal or
external thread) and the tightening torques may therefore also
differ. The tightening torque for the valves -3- used at present
with an M10 x 1.25 mm internal thread is 9 Nm +- 1 Nm.
♦ There are different versions of these valves and the corre‐
sponding sealing caps. Attention is to be paid to the correct
version of the valve and correct assignment of the sealing cap
2.5 Switches and senders in refrigerant cir‐

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

sures, switch removal/installation and switch layout/design ⇒
Heating, air conditioning; Rep. gr. 87 or ⇒ Air conditioning; Rep.
gr. 87 (vehicle-specific workshop manual).
♦ High-pressure switch for air conditioning system -F23-

⇒ page 29
♦ High-pressure switch for magnetic clutch -F118-
⇒ page 29
♦ Low-pressure switch for air conditioning system -F73-
⇒ page 29
♦ Air conditioning system pressure switch -F129- ⇒ page 30
♦ High-pressure sender -G65- ⇒ page 30
♦ Refrigerant pressure and temperature sender -G395-
⇒ page 31
♦ Connections with valve for refrigerant circuit switches
⇒ page 29
♦ Air conditioner compressor regulating valve -N280-
⇒ page 31
♦ Air conditioning system compressor speed sender -G111-
⇒ page 32

♦ Refrigerant temperature sender -G454- ⇒ page 32
2.5.1 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).
2.5.2 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).
2.5.3 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).
2.5.4 Connections with valve for refrigerant

circuit switches
• There are different threads for switches on high and low-pres‐
sure 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
example (tightening torque ⇒ page 26 ).

2.5.5 Air conditioning system pressure switch

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

high-pressure switch for air conditioning system -F23- , the low-
pressure switch for air conditioning system -F73- and the high-
pressure switch for magnetic clutch -F118- .
2.5.6 High-pressure sender -G65-

The high-pressure sender -G65- is fitted instead of the air condi‐
tioning system pressure switch -F129- or the refrigerant pressure
and temperature sender -G395- .
The refrigerant pressure and temperature sender -G395- ( „grey“
housing at present) and the high-pressure sender -G65- ( „black“
housing at present) currently only differ in terms of the housing
colour and attention is therefore to be paid to the correct assign‐
ment on replacement (part number ⇒ Electronic parts catalogue ).
As these two senders emit different signals, the relevant control
unit can only evaluate the signal to which it has been matched ⇒
The high-pressure sender -G65- generates a square-wave signal
or data telegram when voltage is applied. This signal changes
with the pressure in the system.
The downstream control units (radiator fan control unit, engine
control unit, operating and display unit for Climatronic air condi‐
tioning system -E87- , Climatronic control unit -J255- etc.) use this
signal to calculate the pressure in the refrigerant circuit and to
actuate the radiator fans and the air conditioning system magnetic
clutch -N25- accordingly or to modify actuation of the air condi‐
tioner compressor regulating valve -N280- ⇒ Heating, air condi‐

2.5.7 Refrigerant pressure and temperature

sender -G395-
The refrigerant pressure and temperature sender -G395- is fitted
instead of the high-pressure sender -G65- .
The refrigerant pressure and temperature sender -G395- ( „grey“
housing at present) and the high-pressure sender -G65- ( „black“
housing at present) currently only differ outwardly in terms of the
housing colour and attention is therefore to be paid to the correct
assignment on replacement (part number ⇒ Electronic parts
catalogue ). As these two senders emit different signals, the rel‐
evant control unit can only evaluate the signal to which it has been
matched ⇒ Heating, air conditioning; Rep. gr. 87 or ⇒ Air con‐
ditioning; Rep. gr. 87 (vehicle-specific workshop manual).
When voltage is applied, the refrigerant pressure and tempera‐
ture sender -G395- exchanges information via the air conditioner
data bus ( „Lin bus“) with the corresponding control unit. The rel‐
evant control unit uses this information to calculate the pressure
and temperature in the refrigerant circuit and any faults detected
are signalled to the control unit.
The temperature measured by the refrigerant pressure and tem‐
perature sender -G395- differs on account of the design of -G395-
and the fitting location from the actual temperature of the
refrigerant in the refrigerant circuit. It is therefore not evaluated at
present by all control units and used for air conditioner control ⇒
This information is used for example by the operating and display
unit, Climatronic control unit -J255- to calculate the pressure in
the refrigerant circuit and to actuate the downstream control units
(radiator fan control unit, engine control unit etc.) by way of the
data bus. These control units then regulate, for example, the ra‐
diator fans and engine accordingly ⇒ Heating, air conditioning;
workshop manual).
2.5.8 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 Climatronic air
conditioning system -E87- 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 or ⇒ Air
conditioning; Rep. gr. 87 (vehicle-specific workshop manual).
The pressure in the low-pressure side is influenced by way of the
regulating valve, thus regulating the temperature in the evapora‐
tor.
Note
The air conditioner compressor regulating valve -N280- is part of

the air conditioner compressor and cannot be replaced separate‐
ly.

2.5.9 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
♦ Fitted in Audi vehicles with compressor driven via poly V-belt

and Zexel compressor ⇒ Heating, air conditioning; Rep. gr.
87 or ⇒ Air conditioning; Rep. gr. 87 (vehicle-specific work‐
shop manual).
♦ The logo of the compressor manufacturer „Zexel“ affixed to the
air conditioner compressor was switched as of year of pro‐
duction 2006 (when the manufacturer's name changed) from
„Zexel“ to the new name „Valeo“.
2.5.10 Refrigerant temperature sender -G454-

The refrigerant temperature sender (with a temperature-sensitive
resistor) is installed, for example, in the high-pressure pipe 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
♦ Fitted, for example, on the Audi Q7 with certain engines ⇒ Air

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 ⇒ Air conditioning; Rep. gr. 87 (vehicle-specific work‐
shop manual) and ⇒ Vehicle diagnostic tester ( „Self-
diagnosis“ or „Guided fault-finding“ function for the air
conditioner).
2.6 Electrical components not installed in

refrigerant circuit
♦ Radiator fan control unit -J293- ⇒ page 33

2.6.1 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, ⇒ Heating,
air conditioning; Rep. gr. 87 or ⇒ Air conditioning; Rep. gr. 87
(vehicle-specific workshop manual).
2.7 Pressures and temperatures in refriger‐

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

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

on the instantaneous operating statuses (e.g. engine speed, ra‐
diator fan speed 1, 2, or 3, engine temperature, air conditioner
compressor on or off) as well as environmental influences (e.g.
ambient temperature, humidity, required cooling output).
On vehicles with air conditioner compressor regulating valve -
N280- the pressure on the low pressure end is altered by actuat‐
ing -N280- .
For this reason, the values given in the following table are only
intended as a rough 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;
workshop manual).
At 20 °C with the engine not running, the pressure in the refrig‐
erant circuit is 4.7 bar ⇒ page 3 (vapour pressure table).
Note

♦ Refrigerant circuit with expansion valve ⇒ page 33

♦ Refrigerant circuit with restrictor and reservoir ⇒ page 35
2.7.1 Refrigerant circuit with expansion valve

HP – High-pressure side of refrigerant circuit
LP – Low-pressure side of refrigerant circuit

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 end), reduced
to -7 °C (low-pressure
end)
-3- High-pressure switch / Liquid approx. 14 bar approx. +55 °C
high-pressure sender
-4- Service connection/ Liquid approx. 14 bar approx. +55 °C
high-pressure end
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- Pressure relief valve Gas approx. 14 bar approx. +65 °C
and
-8- Air conditioner com‐
pressor/high-pressure
end
-9- Air conditioner com‐ Gas approx. 1.2 bar 1)1 approx. -1 °C 2)2
pressor/low-pressure end
-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 end
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 103 .
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 103 .
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 end 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
pipe 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 22 .


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

reservoir
centigrade
-1- Air conditioner com‐ Gas Up to 20 bar Up to +70 °C
pressor/high-pressure
end
-2- Condenser From gas to vapour to liq‐ Up to 20 bar Up to +70 °C
uid
-3- Restrictor From liquid to vapour HP end up to 20 bar LP HP end up to +60 °C LP
end 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


centigrade
-6- Air conditioner com‐ Gas
pressor/low-pressure end
The pressures on the low-pressure end are maintained at approx.
2 bar absolute (corresponding to approx. 1 bar gauge) by the
„regulating“ air conditioner compressor even at varying engine
speeds. This however only applies within the output range of the
air conditioner compressor. If the output limits of the air condi‐
tioner compressor are exceeded, refer to ⇒ page 103 .
Note
On vehicles with air conditioner compressor regulating valve -

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


high-pressure end
2 - Condenser
3 - Restrictor
4 - Evaporator
5 - Reservoir
low-pressure end

2.8 Test and measurement operations

which can be performed with a pressure
gauge
Pressure gauge scales
1- Temperature scale for refrigerant R134a CF3– CH2F or
CH2F– CF3
2- Pressure scale
Note

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.
♦ Pressure gauges permit the following test and measurement
operations ⇒ page 37 .
2.8.1 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.

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.
2.9 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 flushing the refrigerant circuit ⇒ page 59 .
♦ Classification of extraction systems ⇒ page 38
♦ Charging systems that do not require a permit ⇒ page 38
2.9.1 Classification of extraction systems
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 unit operation
and maintenance can be found in the relevant manufacturer's
documentation.
♦ Extraction and charging systems of groups „1“ and „2“ are not
used in motor vehicle workshops.
Group „3“ extraction and charging systems:

Mobile extraction and charging systems for filling compressed-
gas vessels permanently connected to the system
The refrigerant or refrigerant/oil mixture is transferred to com‐
pressed-gas vessels which are permanently connected to the
mobile systems. In line with § 3 Para. 5 No. 3 of the German
pressure vessel regulations (different regulations may apply in
other countries), compressed-gas vessels are classified as pres‐
sure 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).
2.9.2 Charging systems that do not require a

permit
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.
TRG 402 (technical regulations for compressed gases) must be
observed when filling other compressed-gas vessels with com‐
pressed gases.
2.10 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 189 .
• Requires compliance with the basic instructions for use of leak
detectors ⇒ page 87 .
• Requires expert knowledge.
Note
Releasing refrigerant into the environment is prohibited

⇒ page 40 (laws and regulations).

3 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.
♦ Laws and regulations ⇒ page 40
3.1 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. 2037/2000
♦ 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

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.
TRG (technical regulations for compressed gases) 400, 401, 402
Note
Only excerpts from the TRG are given in the following (sections
applicable to motor vehicle manufacturers and workshops).
♦ TRG 400 (general regulations for charging systems)

– Definition of terms and explanatory notes
– Charging systems
– Charging systems are systems for filling mobile compressed-
gas vessels. The charging system includes the premises and
facilities concerned.
– Charging systems requiring a permit
Note
♦ 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.
♦ TRG 401 (installation of charging systems)

– Does not apply to vehicle manufacturers or workshops.
♦ TRG 402 (operation of charging systems)
– Employees and the instruction of employees
Note
Employees are to be given instruction on the following topics be‐

fore 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 TRG
• Procedures in the event of malfunction, damage and accidents
3. Laws and regulations 41

• 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
persons:
– 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.
Charging (a special TRG applies to vessels from other countries

and charging of these).
♦ 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 TRG 104 must be marked on the vessel prior to con‐
nection for filling.
♦ Compressed-gas vessels marked with the maximum permis‐
sible charge pressure in bar at 15 °C must be filled manomet‐
rically. If, at the time of filling, the temperature is not 15 °C, the
pressure corresponding to the prevailing temperature must be
established; it must be ensured that the permissible charge
pressure at 15 °C is not exceeded in the compressed-gas
vessel. The charged vessels must be checked by way of ran‐
dom pressure measurements to determine possible overfill‐
ing.
♦ Compressed-gas vessels on which the maximum permissible
capacity is indicated by the net weight (filling weight, permis‐
sible weight of fill) in kilograms must be filled gravimetrically.
The vessels must be weighed during filling and subsequently
subjected to a weight check on special scales to detect pos‐
sible overfilling. Scales used for this purpose must be calibra‐
ted.
♦ Under certain conditions, gases with a tc ≥ +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 TRG apply
to the transfer of liquefied gas to cylinders used by workmen.
♦ The following TRG apply to vessels in vehicles:
– TRG 101 to gases with a tc ≥ +70 °C.
– TRG 102 or TRG 103 to industrial gas mixtures with a tc ≥
+70 °C:
– Liquefied extremely low-temperature compressed gases (re‐
fer to TRG 103) 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 tem‐
perature of the charge. When filling volumetrically, it must be
ensured that the permissible charge weight indicated on the

vessel is not exceeded. To determine possible overfilling, the

charged vessels are to be checked gravimetrically on calibra‐
ted scales or volumetrically, provided that the compressed
gases are not highly toxic. Volumetric checking requires the
use of appropriate equipment with completely separate charg‐
ing 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.
♦ Items 4 to 7 do not apply to vessels for liquefied, extremely
low-temperature compressed gases which are neither flam‐
mable nor toxic; this does not affect the provisions of road
traffic legislation.
♦ When filling compressed gas vessels with liquified gases at
charging temperatures ≤ -20 °C, the compressed gas vessel
(if the vessel material has not been tested for temperatures ≤
-20 °C) is not to be released from the charging system for
transportation until the vessel wall temperature is ≥ +20 °C.
Recycling and refuse law
♦ Regulations and rules for the handling and disposal of refrig‐
erants and refrigerant oils can be found in the climate protec‐
tion regulation on chemicals and in the recycling and refuse
law (applicable in Germany, different regulations and rules
may apply in other countries).
Disposal of refrigerant
Refrigerants intended for disposal are to be transferred 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 (different regulations and rules may apply in other countries).
Disposal of refrigerant oil
Used refrigerant oils from systems employing halogenated hy‐
drocarbons are to be disposed of as waste requiring special
monitoring. They are not to be mixed with other oils or substan‐
ces. Proper storage and disposal must be ensured in line with
local regulations. In Germany, reference should be made for ex‐
ample to the climate protection regulation on chemicals and the
recycling and refuse law (different regulations and rules may ap‐
ply in other countries) ⇒ Audi-ServiceNet, HSO Environmental
Protection .
♦ Conversion of an R12 refrigerant circuit to an R134a refriger‐
ant circuit and servicing (retrofit) ⇒ page 44
♦ Keeping refrigerant records ⇒ page 44
3. Laws and regulations 43

3.1.1 Conversion of an R12 refrigerant circuit

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

ing legislation, refrigerant R12 can no longer be manufactured
or supplied. Refrigerant R134a has been developed as a re‐
placement for R12.
♦ Air conditioning systems developed and designed for refriger‐
ant R12 cannot however 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).
3.1.2 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 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 re‐
cord sheet for the quantity of refrigerant handled in motor vehicle
workshops. Other regulations may apply in countries not belong‐
ing to the EC.

4 Refrigerant circuit
♦ Important repair notes for air conditioning systems
⇒ page 45
♦ Conversion of refrigerant circuits from refrigerant R12 to
R134a ⇒ page 45 .
♦ Working with the air conditioner service station ⇒ page 46 .
♦ Blowing out the refrigerant circuit with compressed air and ni‐
trogen ⇒ page 55 .
♦ Flushing (cleaning) the refrigerant circuit with refrigerant
R134a ⇒ page 59 .
♦ Determination of refrigerant circuit leaks ⇒ page 87 .
4.1 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 44 and ⇒ Workshop Manual: Air conditioner with re‐
frigerant R12 Part 2 and 3 . This Workshop Manual is only
available in hardcopy form.
• The refrigerant oils specifically developed for R134a and R12
refrigerant circuits are never to be mixed.
• Air conditioner service stations which come into contact with
the refrigerant should only be used for the intended refrigerant.
• The components of an R134a refrigerant circuit are accord‐
ingly labelled, marked with green stickers or designed (e.g. a
different thread) such that interchange with components for
refrigerant R12 is not possible.
• 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 13 and „Basic rules for working on refrigerant circuit“
⇒ page 14 .
4.2 Converting refrigerant circuits from re‐

frigerant R12 to refrigerant R134a
CFC refrigerants are no longer used in the automotive industry.
For conversion of refrigerant circuits from R12 to R134a and
servicing converted circuits, refer to
⇒ Workshop Manual: Air conditioner with refrigerant R12 Parts 2
and 3 (this Workshop Manual is only available in printed form).
4. Refrigerant circuit 45
4.3 Working with the air conditioner service

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

additives) for sealing leaks have been added to the refrig‐
erant circuit from which the refrigerant is to be extracted,
do not connect the air conditioner service station to this
refrigerant circuit and do not extract the refrigerant.
♦ Chemical substances (sealing additives) for sealing leaks
form deposits in the refrigerant circuit which will impair
operation of the air conditioning system and lead to failure
of the system (and of the air conditioner service station).
♦ Customers should be informed that the air conditioner in
their vehicle contains substances not approved by Audi
and that the system can therefore not be discharged and
serviced by your workshop.
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.
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 objects to the
use of these substances, no statement can be made regarding
the effectiveness and the interception rate of these filters.
♦ Important notes for working with the air conditioner service

station ⇒ page 47 .
♦ Connection of the air conditioner service station for measure‐
ment and testing ⇒ page 47 .
♦ Refrigerant circuit discharge using the air conditioner service
♦ Refrigerant circuit evacuation using the air conditioner service
♦ Refrigerant circuit charging using the air conditioner service
♦ Air conditioner start-up after charging ⇒ page 53 .
♦ Pouring refrigerant into the charging cylinder or storage vessel
of the air conditioner service station ⇒ page 54 .
♦ Air conditioner service station drainage ⇒ page 55 .

4.3.1 Important notes for working with the air

conditioner service station
The following must be heeded with regard to operation of air con‐
ditioner service stations (e.g. V.A.G 1885; for currently available
air conditioner service stations, refer to ⇒ V.A.G workshop equip‐
ment catalogue ):
– The filters and dryers fitted must be replaced at the latest at
the end of the period of use specified in the corresponding
operating instructions.
– If an air conditioner service station is also used to flush the
refrigerant circuit, the dryers and filters fitted must be renewed
more frequently ⇒ page 55 .
– 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) ⇒ Elec‐
tronic 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, the air conditioner service station is to be
drained ⇒ page 99 , the system cleaned if necessary and the
filters, dryers and refrigerant oil replaced.
– In Germany, for example, contaminated refrigerant can be re‐
turned to the refrigerant supplier in so-called recycling bottles
for recycling or ecological disposal (other or additional regu‐
lations 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), e.g. V.A.G 1885 (for currently available air
conditioner service stations, refer to ⇒ V.A.G workshop equip‐
ment catalogue ).
♦ Air conditioner service stations which transfer extracted re‐
frigerant to recycling containers (for large-scale recycling);
these are referred to as extraction systems.
4.3.2 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
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, these are to be connected 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 or ⇒ Air
– 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 end

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

adapter to the extent required to reliably open the valve in the
service connection (observe the pressure gauge; take care not
to open the valve too far).
– Start the engine and perform the intended tests and meas‐
urements.
– Compare the values determined to the specified measured
values ⇒ page 103 .
– Before detaching quick-release coupling, close it by screwing
out handwheel.
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 99 .
– The charging hose must be fitted with a valve opener to open

the valve in the valve adapter.
4.3.3 Discharging refrigerant circuit with air

• Work procedure may vary depending on the type of tools se‐
lected; it is therefore important to observe the tool-specific
• 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 the 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 or ⇒ Air condi‐
tioning; Rep. gr. 87 (vehicle-specific workshop manual).

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 144 .
♦ On vehicles fitted with an air conditioner compressor with no
magnetic clutch (with an air conditioner compressor regulating
valve -N280- ), the engine should not be run for longer than
absolutely necessary with the refrigerant circuit empty and
high engine speeds are to be avoided (constant air conditioner
compressor operation).
♦ 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).
compressor is switched on (or the refrigerant circuit is dis‐
charged via the low-pressure end), the pressure on the low-
pressure end decreases, the expansion valve opens and the
refrigerant can flow to the low-pressure end.
4.3.4 Evacuating refrigerant circuit with air

• The work procedure must always be performed as described
in the operating instructions of the air conditioner service sta‐
tion.
• Quantity of refrigerant oil in refrigerant circuit checked and if
necessary corrected ⇒ page 144 .
• Quantity of refrigerant in air conditioner service station
checked
The refrigerant circuit must be evacuated before it is filled with
refrigerant. Moisture is also extracted from the circuit.
Leaks can be detected on evacuating the refrigerant circuit.
Evacuating:
Caution
♦ Do not start the engine during the evacuating procedure

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

– Connect 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 or ⇒ Air conditioning;
Rep. gr. 87 (vehicle-specific workshop 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 99 .
– Switch on the air conditioner service station and evacuate the

refrigerant circuit for at least 30 minutes. In this process, the
pressure reading must be less than 10 mbar absolute (corre‐
sponding to a vacuum of 990 mbar).
Note
On the air conditioner service station V.A.G 1885 (for currently

available air conditioner service stations, refer to ⇒ V.A.G work‐
shop equipment catalogue ), the two green LEDs light at this
pressure for example.
– Switch off air conditioner service station and allow to stand for
at least 1 hour.
• If the vacuum display (LED chain) does not change, the sys‐
tem is free of leaks and can be charged.

Note
♦ With V.A.G 1885 for example (for currently available air con‐
ditioner service stations, refer to ⇒ V.A.G workshop equip‐
ment catalogue ), a current 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:
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 55 . 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 195 . 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- ⇒ Workshop equipment catalogue .
♦ By using a pressure gauge set with pressure reducer for ni‐
trogen (maximum reducing pressure: 15 bar) -1-, a com‐
pressed air cylinder -3- filled with nitrogen can be connected
by way of a charging hose -2- (e.g. with a 5/8"-18 UNF thread)
to the service connection (to which a quick-release coupling
adapter for service connections has been attached) at the
closed refrigerant circuit ⇒ page 194 .
– Slowly increase the pressure in the refrigerant circuit to max.

15 bar.
WARNING
♦ Maximum permissible operating pressure 15 bar

♦ For leak detection with nitrogen always work with pressure
reducers for nitrogen cylinders.
– Determine the leakage location by way of the noise caused by

the escaping gas at this point.
– Eliminate the leakage.
– Evacuate and again observe the vacuum display over a period
of hours. Charging may only be carried out if vacuum is main‐
tained.
♦ In the event of a leakage of a magnitude permitting the ingress
of no or very little air and the air conditioner service station can
generate an adequate vacuum. The vacuum display does not
increase or only increases very slowly after switching off the
air conditioner service station, indicating that air is only in‐
gressing and vacuum is being lost through a minor leak.
– Pour 100 g of refrigerant into the circuit and use an electronic
leak detector to locate and eliminate any leak ⇒ page 88 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 89 .
– Discharge the refrigerant circuit if necessary ⇒ page 48 .

– 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.
4.3.5 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 144 .

tion.
• Before pouring in refrigerant, correct the quantity of refrigerant
oil ⇒ page 144 .
• 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.
– Evacuate refrigerant circuit with air conditioner service station
⇒ page 49 .
– Unscrew handwheel at quick-release coupling adapter (to
close it).
– 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.
4.3.6 Starting up air conditioner after charging
Note
If it has been removed, give the air conditioner compressor ap‐

prox. 10 turns by hand prior to initial start-up to prevent damage
caused by fluid lock when first switched on (any oil in the air con‐
ditioner compressor cylinder is forced out by the cranking action).
– 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 stabilize.
– Switch on the air conditioner compressor and operate the sys‐
tem for at least 2 minutes at idling speed.
– If necessary, check pressures in refrigerant circuit with air
conditioner service station.
– Switch off engine.
– Screw out handwheel on quick-release coupling adapter.
– Detach the charging hoses from the refrigerant circuit.
– Screw the sealing caps back on.
4.3.7 Pouring refrigerant into reservoir (charg‐

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

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

vessel will explode when the temperature rises.

4.3.8 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 replaced (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 before 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).
4.4 Blowing out refrigerant circuit with com‐

pressed air and nitrogen
The best way of removing moisture, impurities and old refrigerant
oil from the refrigerant circuit without any unnecessary loss of re‐
frigerant and without extensive assembly work, whilst at the same
time ensuring environmental compatibility, is to flush the refriger‐
ant 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 flushing with re‐
frigerant R134a. Flushing with refrigerant R134a also provides
far better cleaning of the components. Flushing should there‐
fore 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 flushing with refrigerant
R134a ⇒ page 59 .
♦ A maximum working pressure of 15 bar is not to be exceeded
when blowing out (corresponds to the pressure prevailing in a
charged refrigerant circuit at an ambient temperature of ap‐
prox. 60 °C; use pressure reducer for compressed air as well
if applicable).
WARNING
♦ Always work with pressure reducers for nitrogen cylinders

(max. working pressure 15 bar).
♦ Use appropriate extraction units to draw off gas mixture
escaping from components.
– Always flush or blow out components in direction opposite to

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

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

integrated receiver, this cartridge is to be removed.
Note
♦ In the case of condensers with an integrated receiver / dryer

cartridge which cannot be renewed separately, the condenser
is to be replaced after flushing.
♦ Depending on the version, receivers on which the dryer car‐
tridge can be replaced separately may be provided with an
additional filter element which may have to be replaced to‐
gether with the dryer 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 99 .
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 filters and dryers for compressed air (included in the scope
of delivery as tool for painting work) ⇒ Workshop equipment
and special tools catalogue .
– For refrigerant pipes 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.
Note
♦ The refrigerant circuit is only to be blown out with compressed

air and then nitrogen if no means of flushing the refrigerant
circuit are available or if flushing of individual components
would involve too much work (blowing minor impurities and
small quantities of moisture out of refrigerant pipes for exam‐
ple is not particularly time-consuming).
♦ Compressed air/nitrogen emerging from the components is to
be drawn off by way of an appropriate system (e.g. workshop
extraction system).
The refrigerant circuit (or individual components) is/are to be

blown out if no means of flushing are available or if flushing 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
count of internal damage (e.g. noise or no output)
– 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 flushing with
refrigerant R134a ⇒ page 59 .
♦ Blowing out refrigerant circuit ⇒ page 58
4.4.1 Blowing out refrigerant circuit
Note
♦ In the case of vehicles on which the refrigerant lines have no

threads for connection of adapters V.A.G -1785- , use is to be
made, for example, for blowing out the individual components
of a blow-out gun with rubber mouthpiece or an adapter from
the VW/Audi passenger vehicle adapter set -VAS 6338/1- .
Special care must be taken not to damage the connections
(crushing or scratching) when using a blow-out gun with rub‐
ber mouthpiece.
♦ The evaporator is to be blown out by way of the connection for
the low-pressure pipe (large diameter) after detaching the ex‐
pansion valve or removing the restrictor.
♦ Always flush or blow out components in direction opposite to
refrigerant flow.
♦ Check expansion valve and renew if dirty or corroded.
♦ If dark, sticky deposits cannot be removed with compressed
air, 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 dryer cartridge in
the integrated receiver, this cartridge is to be replaced.
cartridge which cannot be replaced separately or which is not
available as a replacement part, the condenser must be re‐
placed after flushing ⇒ Electronic parts catalogue and ⇒
Rep. gr. 87 .
After blowing out the refrigerant circuit:

– Replace the vehicle-specific components (restrictor and res‐
ervoir, expansion valve and receiver or dryer cartridge) ⇒
Rep. gr. 87 (vehicle-specific workshop manual) and ⇒ Elec‐
– Depending on the problem, replace the air conditioner com‐
pressor ⇒ Heating, air conditioning; Rep. gr. 87 or ⇒ Air
and ⇒ Electronic parts catalogue or drain off the remaining
refrigerant oil from the air conditioner compressor removed
⇒ page 136 (replace refrigerant circuit components) and add
the specified quantity of fresh refrigerant oil again
⇒ page 164 (approved refrigerant oils and refrigerant oil ca‐
pacities).

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 or ⇒
Air conditioning; Rep. gr. 87 (vehicle-specific workshop man‐
ual) and ⇒ page 164 (approved refrigerant oils and refrigerant
oil capacities).
♦ If the air conditioner compressor is not to be replaced, 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 136 (re‐
place refrigerant circuit components) and ⇒ page 164 (ap‐
proved refrigerant oils and refrigerant oil capacities).
– Completely re-assemble the refrigerant circuit ⇒ Heating, air

conditioning; Rep. gr. 87 or ⇒ Air conditioning; Rep. gr. 87
– Evacuate and charge the refrigerant circuit as specified
⇒ page 49 and ⇒ page 53 .
– Start up the air conditioner as specified ⇒ Heating, air condi‐
specific workshop manual) and ⇒ page 53 .
4.5 Flushing (cleaning) refrigerant circuit

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

additives) for sealing leaks have been added to the refrig‐
erant circuit to be flushed, do not connect the air condi‐
tioner service station to this refrigerant circuit and do not
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 flushed and
serviced by your workshop.
Note
♦ Audi does not permit the use of chemical substances (sealing

additives) to seal leaks in the refrigerant circuit.
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 flushing). The refrigerant circuit can therefore only be
repaired by replacing all the components which have come
into contact with this substance.
the refrigerant circuit are normally not outwardly apparent and
the identification stickers which should be affixed for this pur‐
pose are usually non-existent. Vehicles with an unknown his‐
tory should therefore be treated with due caution.
• 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 flush the refrigerant circuit
with refrigerant R134a.
The refrigerant circuit is to be flushed:
– In there is any dirt or similar in the circuit.
– 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
count of internal damage (e.g. noise or no output)
– If stipulated by the vehicle-specific Workshop Manual after re‐
newing certain components
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) ⇒ Workshop equipment and
special tools catalogue
♦ Adapter set for refrigerant circuits -VAS 6338/1- ⇒ page 71
and ⇒ Workshop equipment and special tools catalogue
♦

Note
♦ If no air conditioner service station with flushing attachment is

available ⇒ Workshop equipment and special tools catalogue
and depending on the version of the air conditioner service
station being used, the refrigerant circuit can also be flushed
with this employing the refrigerant circuit flushing attachment
⇒ Workshop equipment and special tools catalogue , however
flushing must then be performed manually. ⇒ page 65
♦ 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 48 .
– Remove the air conditioner compressor ⇒ Heating, air condi‐
Vehicle with restrictor and reservoir
– Remove restrictor (vehicle-specific) and re-connect pipes ⇒
Rep. gr. 87 (vehicle-specific Workshop 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 71 , ⇒ Heating, air con‐
ditioning; Rep. gr. 87 or ⇒ Air conditioning; Rep. gr. 87
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

– 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 71 , ⇒ Heating, air conditioning; Rep. gr. 87 or ⇒
ual).
Note
♦ Depending on design, the receiver can be flushed (remove the

fitted dryer cartridge if applicable) ⇒ page 71 , ⇒ Heating,
87 (vehicle-specific workshop manual).
♦ If the receiver is attached to the condenser (e.g. on Audi A3
as of Model Year 2004), it is not removed for flushing (its de‐
sign makes it suitable for flushing and it is only replaced after
flushing) ⇒ page 71 and ⇒ Heating, air conditioning; Rep.
workshop manual).
cartridge which cannot be renewed separately or which are
not available separately, the condenser is to be replaced after
flushing. On these vehicles, the condenser is then to be re‐
placed together with the receiver ⇒ Heating, air conditioning;
Rep. gr. 87 and ⇒ Electronic parts catalogue .
– On vehicles with a dryer cartridge in the receiver at the con‐

denser (vehicle-specific), remove the dryer cartridge and re-
seal the opening at the receiver ⇒ Heating, air conditioning;
workshop manual).
– Remove the expansion valve (vehicle-specific) and replace it
with an adapter from the VW/Audi passenger vehicle adapter
set -VAS 6338/1- ⇒ page 71 , ⇒ Heating, air conditioning;
workshop manual).

Note
♦ If there is no suitable adapter for the expansion valve in the

VW/Audi passenger vehicle adapter set -VAS 6338/1- , the
expansion valve removed can also be drilled open (the old
expansion valve generally has to be replaced and is therefore
no longer needed).
♦ 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).
♦ 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 71 , ⇒ Heating, air
conditioning; Rep. gr. 87 or ⇒ Air conditioning; Rep. gr. 87 (ve‐
hicle-specific workshop manual).
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 end) of the air con‐
ditioner service station with an adapter to the low-pressure
pipe to the air conditioner compressor (pipe with larger diam‐
eter) ⇒ page 71 .
– 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 pipe to the air conditioner
compressor (pipe with smaller diameter) ⇒ page 71 .
Note
♦ The components are always flushed in the direction opposite

to that of refrigerant flow during air conditioner operation
⇒ page 67 .
♦ 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,
these components are to be replaced more frequently in line
with 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), the filter is to be replaced. In the case of
such severely contaminated refrigerant circuits it is also ap‐
propriate to flush the circuit again after replacing 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 at the necessary rate
through the expansion valve, restrictor and desiccant bag of
certain receivers. These components are therefore to be re‐
moved and replaced with adapters if applicable ⇒ Heating, air
♦ Adapters for connection of air conditioner service station and
for bridging certain refrigerant circuit components
⇒ page 71 .
– Switch on the air conditioner service station and flush the re‐
frigerant circuit (duration approx. 1 to 1.5 hours for one flushing
cycle with three flushing operations).

Note
♦ The flushing operation is to be performed in line with the op‐

erating instructions for the air conditioner service station.
♦ Depending on the version of the air conditioner service station,
the used oil container may only hold approx. 125 cm3 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 sta‐
tion, manual switching to next step may be necessary).
♦ A specified quantity of refrigerant (e.g. 5 kg) is added to the
evacuated refrigerant circuit via the high-pressure end of the
air conditioner service station (in the direction opposite to the
normal flow direction during air conditioner operation and thus
on the low-pressure end of the vehicle refrigerant circuit) or
refrigerant is added until the refrigerant circuit and the inspec‐
tion ports of the refrigerant circuit flushing 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
♦ The refrigerant charging, extraction (and evacuation) process
is repeated twice (in other words it is implemented a total of
three times).
♦ 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).
– 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).
– Replace the vehicle-specific components (restrictor and res‐
ervoir, expansion valve and receiver or dryer cartridge in the
receiver) ⇒ Heating, air conditioning; Rep. gr. 87 or ⇒ Air
– Depending on the problem, replace the air conditioner com‐
pressor ⇒ Heating, air conditioning; Rep. gr. 87 or ⇒ Air
and ⇒ Electronic parts catalogue or drain off the remaining
refrigerant oil from the air conditioner compressor removed
⇒ page 136 (replace refrigerant circuit components) and add
the specified quantity of fresh refrigerant oil again
⇒ page 164 (approved refrigerant oils and refrigerant oil ca‐
pacities).
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 or ⇒
ual) and ⇒ page 164 (approved refrigerant oils and refrigerant
oil capacities).
♦ If the air conditioner compressor is not to be replaced, 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 136 (re‐
placing refrigerant circuit components) and ⇒ page 164 (ap‐
proved refrigerant oils and refrigerant oil capacities).
– Completely re-assemble the refrigerant circuit ⇒ Heating, air

– Start up the air conditioner as specified ⇒ Heating, air condi‐
specific workshop manual) and ⇒ page 53 .
♦ Block diagrams for various flushing circuits ⇒ page 67
♦ Adapters for connecting flushing circuits ⇒ page 71

4.5.1 Block diagrams for various flushing cir‐

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

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

ervoir are removed and the pipes unfastened to remove the
restrictor are connected back together. The pipe connections to
the reservoir removed are connected together with two adapters
and the charging hose -VAS 6338/31- (from the VW/Audi pas‐
senger vehicle adapter set -VAS 6338/1- ).
1 - Air conditioner service sta‐

tion
❑ With electronics and a
flushing program, e.g.
Air conditioner service
station with flushing at‐
tachment ⇒ Workshop
equipment and special
tools catalogue
❑ If use is made of an air
conditioner service sta‐
tion with no flushing pro‐
gram, the process is to
be implemented man‐
ually (evacuation, 3x
flushing with at least 4
kg of refrigerant each
time, extraction of refrig‐
erant again, evacua‐
tion).
2 - Refrigerant hose of air con‐
❑ From the high-pressure
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) at refriger‐
ant circuit
pending on vehicle
⇒ page 71
❑ From adapter set for re‐
frigerant circuits -VAS 6338/1-
4 - Connection (low-pressure side) at refrigerant circuit
❑ Different versions depending on vehicle ⇒ page 71
❑ At the refrigerant pipe from the air conditioner compressor to the reservoir
5 - Connection to reservoir
❑ At the refrigerant pipe from the air conditioner compressor to the reservoir
6 - Adapter for bridging reservoir after removal
❑ From adapter set for refrigerant circuits -VAS 6338/1-
7 - Filler hose for refrigerant ⇒ page 71
❑ For example filler hose -VAS 6338/31- (from adapter set for refrigerant circuits -VAS 6338/1- )
8 - Adapter for bridging reservoir after removal
9 - Connection to reservoir

10 - Evaporator
11 - Fitting location for restrictor
❑ Restrictor removed.
❑ Remove the restrictor ⇒ Heating, air conditioning; Rep. gr. 87 or ⇒ Air conditioning; Rep. gr. 87 (vehicle-
12 - Bolt connection in refrigerant line
❑ Screw back together following restrictor removal ⇒ Heating, air conditioning; Rep. gr. 87 or ⇒ Air
13 - Condenser
14 - Connection (high-pressure side) at refrigerant circuit
15 - Adapter for connection (high-pressure side) at refrigerant circuit
16 - Filler hose to flushing kit for refrigerant circuits
❑ From the high-pressure end connection of the air conditioner compressor at the refrigerant circuit (smaller
diameter) to the inlet of the refrigerant circuit flushing attachment.
17 - Flushing kit for refrigerant circuits
❑ Different versions and different design of flushing kit for refrigerant circuits ⇒ Workshop equipment and
❑ 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.
1 - Air conditioner service sta‐

tion
❑ With electronics and
flushing program, Air
tion with flushing kit ⇒
Workshop equipment
and special tools cata‐
logue
❑ If use is made of an air
tion with no flushing pro‐
gram, the process is to
be implemented man‐
ually (evacuation, 3x
flushing with at least 4
kg of refrigerant each
time, extraction of refrig‐
erant again, evacua‐
tion).
2 - Refrigerant hose of air con‐
❑ From the high-pressure
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) at refriger‐
ant circuit
pending on vehicle
⇒ page 71
❑ From adapter set for re‐
frigerant circuits -VAS 6338/1-
4 - Connection (low-pressure side) at refrigerant circuit
5 - Adapter for removed expansion valve
6 - Evaporator
7 - Connection to receiver
❑ Not fitted on vehicles with a dryer cartridge in the receiver at the condenser or with a receiver installed
in the condenser ⇒ Heating, air conditioning; Rep. gr. 87 or ⇒ Air conditioning; Rep. gr. 87 (vehicle-
8 - Adapter for bridging removed receiver
❑ Not necessary on all vehicles
9 - Filler hose for refrigerant ⇒ page 71
❑ For example filler hose -VAS 6338/31- (from adapter set for refrigerant circuits -VAS 6338/1- )

10 - Condenser
❑ If a receiver with dryer cartridge is fitted at the condenser, the dryer cartridge must be removed (seal
receiver at or in condenser again following removal) ⇒ Heating, air conditioning; Rep. gr. 87 or ⇒ Air
conditioning; Rep. gr. 87 vehicle-specific workshop manual).
❑ If the receiver is attached directly to the condenser, the receiver is only to be removed and replaced after
flushing ⇒ Heating, air conditioning; Rep. gr. 87 or ⇒ Air conditioning; Rep. gr. 87 (vehicle-specific
workshop manual).
Note
11 - Connection (high-pressure side) at refrigerant circuit

12 - Adapter for connection (high-pressure side) at refrigerant circuit
13 - Filler hose to flushing kit for refrigerant circuits
❑ From the high-pressure end connection of the air conditioner compressor at the refrigerant circuit (smaller
diameter) to the inlet of the refrigerant circuit flushing attachment.
14 - Flushing kit for refrigerant circuits
❑ Different versions and different design of flushing kit for refrigerant circuits ⇒ Workshop equipment and
❑ 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
17 - Adapter for sealing outlet to second evaporator
18 - Connection (low-pressure side) at refrigerant circuit to second evaporator
❑ Only fitted on certain vehicles with „second evaporator“ as optional extra
19 - Connection (high-pressure side) at refrigerant circuit to second evaporator
20 - Adapter for expansion valve (removed) at second evaporator
21 - Second evaporator
4.5.2 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 removed
(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, use may have been made of dif‐
ferent connection and sealing methods at the refrigerant circuit
⇒ Heating, air conditioning; Rep. gr. 87 or ⇒ Air conditioning;
Block or screw connections
– Screw connection -A-
– Block connection -B-
Block connections with different types of seal

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

guide -B-)
– Block connection with axial seal -C-
Audi A1 and Audi A2
Vehicle Adapters re‐ Adapters required for Other re‐
quired for the reservoir/receiver con‐ quire‐
connections to nections ments
the air condition‐
er compressor
Audi A1 – Compressor Different versions Expansion
(8X_) manufacturer – Version 1 (integra‐ valve re‐
2011 ► „Denso“, ted receiver at con‐ moved and
„Sanden“ or denser): No adapt‐ adapter -
„Delphi“ er required, the VAS
♦ Low-pres‐ desiccant bag is re‐ 6338/34-
sure end moved from the re‐ fitted (or
Adapter -VAS ceiver at the con‐ old expan‐
6338/12- denser and the sion valve
opening sealed off removed
♦ High-pres‐ again for flushing. drilled
sure end open for
Adapter -VAS – Version 2 (receiver flushing
6338/3- or attached to con‐ and re-in‐
Adapter -VAS denser): No adapt‐ stalled)
6338/2- (de‐ er required, the re‐ ⇒ page 63
pending on ceiver is left in
the design of position (replaced
the compres‐ after flushing)
sor and the
correspond‐
ing refriger‐
ant line)
Audi A2 – Compressor Reservoir - Restrictor

(8Z_) manufacturer – Screw connection removed,
2001 ► „Denso“ at inlet Adapter - pipe con‐
♦ Adapter -VAS VAS 6338/9- nections
6338/12- re-assem‐
(low-pres‐ – Block connection bled
sure side) with axial seal at
outlet Adapter -
♦ Adapter -VAS VAS 6338/10-
6338/2-
(high-pres‐
sure side)
Note
On the Audi A1, the receiver may be attached or integrated de‐

pending on the version of the condenser. The integrated receiver
is fitted with a dryer cartridge which can be replaced separately.
If the receiver is of the attached type (introduction not yet final‐
ised), it must be replaced after flushing ⇒ Electronic parts cata‐
logue and ⇒ Heating, air conditioning; Rep. gr. 87 .
Audi A3 and Audi TT

quired for the reservoir/receiver con‐ quire‐
connections to nections ments
er compressor
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 -VAS 6338/2- (2x re‐ 6338/19-
6338/7- (low- quired) fitted (or
pressure drilled-
side) open ex‐
pansion
♦ Adapter -VAS valve e.g.
6338/2- 6N0 820
(high-pres‐ 679 C fit‐
sure side) ted
⇒
page 63 )
Audi A3 – Compressor Receiver (different ver‐ Expansion
(8P_) manufacturer sions) valve re‐
2004 ► for Audi A3 – Adapter not re‐ moved and
Audi TT „Sanden“, quired, receiver re‐ Adapter -
(8J_) „Denso“, mains in position VAS
2007 ► „Delphi“ or 6338/18-
„Zexel / Va‐ – Depending on the (or drilled-
leo“ version of the con‐ open ex‐
– Compressor denser, it may be pansion
manufacturer necessary to re‐ valve e.g.
for Audi TT move the dryer car‐ 1K0 820
„Denso“ tridge from the re‐ 679) fitted
♦ Adapter -VAS ceiver at the con‐ ⇒ page 63
6338/12- denser before
(low-pres‐ flushing and to seal
sure side) the opening again
(refer to note).
♦ Adapter -VAS
6338/3-
(high-pres‐
sure side)
Note
♦ The design of the receiver on the Audi A3 and Audi TT differs

depending on the condenser manufacturer. The Audi TT with
5-cyl. engine is fitted for example with a different type of con‐
denser to vehicles with a 4 or 6-cyl. engine. This condenser
features an integrated receiver for example. The integrated
receiver contains a dryer cartridge which is currently not al‐
ways available as a replacement part. On vehicles fitted with
this condenser, it may therefore be necessary to replace the
entire condenser after rectifying any problems ⇒ Electronic
parts catalogue and ⇒ Heating, air conditioning; Rep. gr. 87 .
flushing (together with the built-in dryer cartridge) ⇒ Heating,
air conditioning; Rep. gr. 87 and ⇒ Electronic parts catalogue .

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

quired for the reservoir connections quire‐
connections to ments
er compressor
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 -VAS with axial seal at
6338/12- outlet Adapter -
(low-pres‐ VAS 6338/10-
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 -VAS let and outlet
6338/12- ♦ Adapter -VAS
(low-pres‐ 6338/10- (2x re‐
sure side) quired)
♦ Adapter -VAS
6338/2-
(high-pres‐
sure side)

er compressor
manufacturer
„Denso“ (bloc – Block connections
k connections with radial seal at
with radial inlet and outlet
seal) ⇒ Air ♦ Adapter -VAS
conditioning; 6338/8- (2x re‐
Rep. gr. 87 quired)
(vehicle-spe‐
cific work‐
shop manual)
♦ Adapter -VAS
6338/12-
(low-pres‐
sure side)
♦ Adapter -VAS
6338/3-
(high-pres‐
sure side)

(8K_) manufacturer sions) valve re‐
2008 ► „Denso“ – Adapter not re‐ moved and
♦ Adapter -VAS quired, receiver re‐ Adapter -
6338/12- mains in position VAS
(low-pres‐ 6338/36-
sure side) – Depending on the (or drilled-
version of the con‐ open ex‐
♦ Adapter -VAS denser, it may be pansion
6338/3- necessary to re‐ valve e.g.
(high-pres‐ move the dryer car‐ 8K0 820
sure side) tridge from the re‐ 679 A) fit‐
ceiver at the con‐ ted
denser before ⇒ page 63
flushing and to seal – The re‐
the opening again friger‐
(refer to note). ant pipe
with in‐
ternal
heat
ex‐
chang‐
er re‐
mains
in posi‐
tion or
is in‐
stalled
again
after fit‐
ting the
adapt‐
er.

Note
♦ The design of the receiver on the Audi A4 (8K_) 2008 > differs
depending on the condenser manufacturer ⇒ Air conditioning;
Rep. gr. 87 . The receiver may be attached or integrated de‐
pending on the version of the condenser. The integrated re‐
ceiver contains a dryer cartridge which is currently not always
available as a replacement part. On vehicles fitted with this
condenser, it may therefore be necessary to replace the entire
condenser after rectifying any problems ⇒ Electronic parts
catalogue .
Audi A5 Coupé and Sportback, Audi Q5, Audi A5 Cabriolet

quired for the receiver connections quire‐
er compressor
Coupé manufacturer sions) valve re‐
and „Denso“ – Adapter not re‐ moved and
Sport‐ ♦ Adapter -VAS quired, receiver re‐ Adapter -
back 6338/12- mains in position VAS
(8T_) (low-pres‐ 6338/36-
2008 ► sure side) – Depending on the (or drilled-
Audi Q5 version of the con‐ open ex‐
(8R_) ♦ Adapter -VAS denser, it may be pansion
2008 ► 6338/3- necessary to re‐ valve e.g.
Audi A5 (high-pres‐ move the dryer car‐ 8K0 820
Cabrio‐ sure side) tridge from the re‐ 679 A) fit‐
let (8F_) ceiver at the con‐ ted
2009 ► denser before ⇒ page 63
flushing and to seal – The re‐
the opening again friger‐
(refer to note). ant pipe
with in‐
ternal
heat
ex‐
chang‐
er re‐
mains
in posi‐
tion or
is in‐
stalled
again
after fit‐
ting the
adapt‐
er.
Note
♦ The design of the receiver differs on these vehicles depending

on the condenser manufacturer ⇒ Air conditioning; Rep. gr.
87 . The receiver may be attached or integrated depending on
the version of the condenser. The integrated receiver contains
a dryer cartridge which is currently not always available as a
replacement part. On vehicles fitted with this condenser, it may
therefore be necessary to replace the entire condenser after
rectifying any problems ⇒ Electronic parts catalogue .

Audi 100, Audi A6, Audi allroad and Audi V8

er compressor
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
manufacturer
and axial – Block connection
seal) with axial seal at
♦ Adapter -VAS outlet Adapter -
6338/12- VAS 6338/10-
(low-pres‐ ♦ Version „3“
sure side) – Block connections
♦ Adapter -VAS with axial seal at in‐
6338/2- let and outlet
(high-pres‐ Adapter -VAS
sure side) 6338/10- (2x re‐
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 -VAS quired)
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.
Audi A7
quired for the receiver connections quire‐
er compressor
(4G_) manufacturer sions) valve re‐
2011 ► „Denso“ – Adapter not re‐ moved and
♦ Low-pres‐ quired, receiver re‐ adapter -
sure end mains in position VAS
Adapter -VAS 6338/36-
6338/12- – Depending on the fitted (or
version of the con‐ old expan‐
♦ High-pres‐ denser, it may be sion valve
sure end necessary to re‐ removed
Adapter -VAS move the dryer car‐ drilled
6338/3- tridge from the re‐ open for
ceiver at the con‐ flushing
denser before and re-in‐
flushing and to seal stalled
the opening again ⇒
(refer to note). page 63 ).
Note
♦ The design of the receiver differs on these vehicles depending

on the condenser manufacturer ⇒ Air conditioning; Rep. gr.
87 and ⇒ Electronic parts catalogue .
flushing (together with the built-in dryer cartridge) ⇒ Air con‐
ditioning; Rep. gr. 87 and ⇒ Electronic parts catalogue .

Audi A8
er compressor
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)

manufacturer
and axial – Block connection
seal) with axial seal at
♦ Low-pres‐ outlet Adapter -
sure end VAS 6338/10-
Adapter -VAS ♦ Version „3“
6338/12- – Block connections
♦ High-pres‐ with axial seal at in‐
sure end let and outlet
Adapter -VAS Adapter -VAS
6338/2- 6338/10- (2x re‐
quired)
Audi A8 – Compressor Reservoir - Restrictor
(4E_) manufacturer – Block connections removed,
♦ Adapter -VAS quired)
6338/12-
(low-pres‐
sure side)
♦ Adapter -VAS
6338/3-
(high-pres‐
sure side)

er compressor
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-
♦ Low-pres‐ opening sealed off fitted (or
sure end again for flushing. old expan‐
Adapter -VAS sion valve
6338/12- removed
drilled
♦ High-pres‐ open for
sure end flushing
Adapter -VAS and re-in‐
6338/3- stalled
⇒
page 63 ).
♦ Addi‐ For flushing the circuit
tio‐ with the evaporator in
nally the front air condition‐
for ing unit
vehi‐ ♦ Adapter -VAS
cles 6338/5- for sealing
with the „low-pressure
2 end“ connection (to
evap‐ the second evapo‐
ora‐ rator)
tors
(4- ♦ Adapter -VAS
zone 6338/11- for seal‐
air ing the „high-pres‐
con‐ sure end“ connec‐
di‐ tion (to the second
tio‐ evaporator)
ner) • An additional hole
may have to be
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-


er compressor
For flushing the sec‐ Expansion
ond evaporator and valve in re‐
the corresponding frigerant
lines lines to
♦ Adapter -VAS second
6338/3- for con‐ evaporator
necting the air con‐ removed
ditioner service sta‐ and adapt‐
tion to the „lower -VAS
pressure end“ con‐ 6338/18-
nection (to the sec‐ fitted (or
ond evaporator). old expan‐
sion valve
♦ Adapter -VAS removed
6338/4- for con‐ drilled
necting the air con‐ open for
ditioner service sta‐ flushing
tion to the „high- and re-in‐
pressure end“ con‐ stalled
nection (to the sec‐ ⇒
ond evaporator). page 63 ).
• The adapter may
have to be re‐
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 hole in adapters -VAS 6338/5- and -VAS

6338/11-
– Make a hole -A- in addition to the hole provided (the dimen‐

sions in the illustration are given in mm).
Reworking adapter -VAS 6338/3-
– By grinding or filing off material in area -A-, rework the adapter

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

Audi Q7
quired for the connections to receiv‐ quire‐
connections to er / to second evapo‐ ments
the air condition‐ rator
er compressor
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 -VAS again. or adapter
evap‐ 6338/12- -VAS
ora‐ (low-pres‐ 6338/33-
tor (2 sure side) fitted de‐
zone pending on
air ♦ Adapter -VAS version of
con‐ 6338/3- expansion
di‐ (high-pres‐ valve (or
tio‐ sure side) drilled-
ner) open ex‐
pansion
valve e.g.
7L0 820
712 A, 7H0
820 679 B
or 7L0 820
679 C fit‐
ted
⇒
page 63 )
⇒ 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)

quired for the connections to receiv‐ quire‐
connections to er / to second evapo‐ ments
the air condition‐ rator
er compressor
For flushing second Expansion
evaporator and corre‐ valve at
sponding pipes second
♦ Adapter -VAS evaporator
6338/3- for con‐ removed
necting the air con‐ and Adapt‐
ditioner service sta‐ er -VAS
tion to the „low- 6338/17-
pressure end“ con‐ fitted (or
nection (to the sec‐ drilled-
ond evaporator). open ex‐
pansion
♦ Adapter -VAS valve e.g.
6338/4- for con‐ 7L0 820
necting the air con‐ 712 A fitted
ditioner service sta‐ ⇒
tion to the „high- page 63 )
pressure end“ con‐ ⇒ Elec‐
nection (to the sec‐ tronic parts
ond evaporator). catalogue
Note
On vehicles with two evaporators, the refrigerant circuit is flushed

in two operations.
Audi R8
er compressor
Audi R8 – Compressor Reservoir - Restrictor
(42_) manufacturer – Block connections removed,
♦ Low-pres‐ quired)
sure end
Adapter -VAS
6338/12-
♦ High-pres‐
sure end
Adapter -VAS
6338/3-

Note
♦ On the Audi R8, the engine must be removed to replace the

air conditioner compressor. For flushing the refrigerant circuit,
the refrigerant pipes can however be detached without remov‐
ing the air conditioner compressor ⇒ Air conditioning; Rep.
♦ The two condensers are flushed in situ in the direction oppo‐
site to that of the refrigerant flow.
4.6 Tracing leaks in refrigerant circuit
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‐
equivocable results and, if not employed in the specified man‐
ner, may indicate leaks at various refrigerant circuit compo‐
nents although these are actually intact. In addition, certain
procedures can lead to damage to components of refrigerant
circuits.
♦ Components found to be leaking are to be replaced and not

repaired.
♦ 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 49 .
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 (even by flushing). The refrigerant
circuit can therefore only be repaired by replacing all the compo‐
nents which have come into contact with this substance.
♦ ⇒ „4.6.1 Tracing refrigerant circuit leaks with electronic leak

detector (e.g. V.A.G 1796)“, page 88 .
♦ ⇒ „4.6.2 Tracing leaks in refrigerant circuit with leak detection
system VAS 6201“, page 89 .
4.6.1 Tracing refrigerant circuit leaks with

electronic leak detector (e.g. V.A.G
1796)
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 49 .
Note
♦ If evacuation already reveals a major leak, this is to be located

and eliminated as described ⇒ page 49 .
♦ 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.
– Pour roughly 100 g of refrigerant into the evacuated refrigerant

circuit.
Detecting leaks:
– Start up leak detector in line with relevant operating instruc‐
tions.
– Always hold test probe beneath suspected leak.
Depending on the model, leak detection is indicated by an in‐
crease in clicking rate or a warning tone (refer to operating in‐
structions for leak detector).
Note
♦ Currents of air quickly disperse refrigerant gas. 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.

4.6.2 Tracing leaks in refrigerant circuit with

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

electronic leak detector. In such cases, the leak detection sys‐
tem VAS 6201 can be used.
♦ Refrigerant circuit leaks result in a loss of refrigerant oil to‐
gether with the refrigerant. This oil generally remains in the
vicinity of the leak location. Adding a small quantity of fluores‐
cent fluid to the refrigerant circuit makes this oil visible under
UV light. The fluid (PAG oil containing an additive which shows
up under UV light) is poured into the refrigerant circuit and
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 end.
♦ If the leak detection additive is applied via the service con‐
nection in the low-pressure side with the refrigerant circuit
charged, a small quantity of additive remains in the service
connection. This is to be carefully removed so as to avoid
subsequent erroneous leak detection.
♦ If a component forming part of a circuit, into which the leak
detection additive has been poured, has to be renewed, thor‐
oughly clean joints with other components after assembling
refrigerant circuit. Otherwise, the residual leak detection ad‐
ditive 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 leak detection additive ingresses into the air conditioner
service station. The refrigerant oil is removed from the refrig‐
erant 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. It is to be replaced with fresh refrigerant oil.
♦ Heed the following if leak detection fluid has already been
poured into a refrigerant circuit in the course of previous repair
work: Only pour in fresh leak detection fluid if the refrigerant
oil is replaced. If only a certain amount of refrigerant oil has
been replaced, just add the corresponding quantity of leak de‐
tection fluid. After replacing 100 ml of refrigerant oil on a
vehicle containing 250 ml for example, just add 1 ml (cm3 ) of
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.
Proceed as follows with a completely empty refrigerant circuit to

avoid allowing more refrigerant than is absolutely necessary for
leak detection to escape into the environment when localising re‐
frigerant circuit leaks:
– Evacuate the refrigerant circuit using the air conditioner serv‐
ice station ⇒ page 49 .
Note
♦ If evacuation already reveals a major leak, this is to be located

and eliminated as described ⇒ page 49 .
♦ 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.
For leakage which cannot be determined by way of evacuation,

refer to ⇒ page 90 .
Tools and other items required:
1- Hand pump with low-pressure service hose, service cou‐
pling and non-return valve -VAS 6201/1-
2- Cartridge -VAS 6201/2-
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- Filler tube
VAS 6201/8
8- Protective gloves -VAS 6201/9-
Pouring in leak detection additive with refrigerant circuit empty

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

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

item -2- -VAS 6201/2- .
– Insert filler tube -VAS 6201/8- ( ⇒ page 90 item -7-) in hand
pump.
– Open hand pump service valve.
Note
♦ When the refrigerant circuit is empty, the leak detection addi‐

tive can be poured into the circuit via a service connection or
an open connection.
♦ If the refrigerant circuit is empty, it may be better to apply the
leak detection additive by way of a joint (e.g. if a joint has al‐
ready been unfastened). In this way, no leak detection additive
is left in the service connection and the connection does not
have to be cleaned.
♦ Application of leak detection additive to the refrigerant circuit

by way of a service connection ⇒ page 93 .
♦ Application of leak detection additive to the refrigerant circuit
by way of an open connection ⇒ page 92 .
Applying 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 leak detection
additive emerges from the tube.
– Fill the refrigerant circuit with 2.5 +/- 0.5 ml (millilitre = cm3) of
Note
Heed the following if leak detection fluid has already been poured
into a refrigerant circuit in the course of previous repair work: Only
pour in fresh leak detection fluid if the refrigerant oil is replaced.
If only a certain amount of refrigerant oil has been replaced, just
add the corresponding quantity of leak detection fluid. After re‐
placing 100 ml of refrigerant oil on a vehicle containing 250 ml for
example, just add 1 ml (cm3 ) of 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.
– Start up the air conditioner.
Note

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

⇒ page 95 .

Pouring in leak detection additive with refrigerant circuit charged
Note
♦ Heed the following if leak detection fluid has already been

poured into a refrigerant circuit in the course of previous repair
work: Only pour in fresh leak detection fluid if the refrigerant
oil is replaced. If only a certain amount of refrigerant oil has
been replaced, just add the corresponding quantity of leak de‐
tection fluid. After replacing 100 ml of refrigerant oil on a
vehicle containing 250 ml for example, just add 1 ml (cm3 ) of
♦ A small quantity of leak detection additive remains in the serv‐
ice connection. This is to be carefully removed so as to avoid
subsequent erroneous leak detection.
The cartridge -A- contains 15.4 ml of leak detection additive (one

unit -B- corresponds to 2.5 ml).

– Detach cap from service connection on low-pressure side of
refrigerant circuit.
– Assemble hand pump -VAS 6201- , item -1- with cartridge,
item -2- -VAS 6201/2- .
– Insert the tube -VAS 6201/8- ( ⇒ page 90 item -7-) in the serv‐
ice 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 leak detection additive starts to
emerge from the tube.
Note
Make sure hand pump hose is completely filled with refrigerant.
– Close service coupling and remove filler tube from locking

mechanism.
– Cover area around service connection on vehicle with sheet‐

ing or absorbent paper.
– Connect filler unit to refrigerant circuit service connection on
vehicle.
– Open service connection by screwing in handwheel.
– Screw in the toggle of the hand pump to transfer 2.5 +/- 0.5 ml
(millilitre= cm3) of leak detection additive to the refrigerant cir‐
cuit.

– Detach filler unit from service connection.

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

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

⇒ page 95 .
Locating refrigerant circuit leaks with UV lamp VAS 6196/4
WARNING
Never look into UV lamp.

Never point UV lamp at other people.
Note
♦ After pouring in the 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 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
⇒ „4.6.1 Tracing refrigerant circuit leaks with electronic leak
detector (e.g. V.A.G 1796)“, page 88 .
– Move vehicle to a less brightly lit area of the workshop (daylight

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

5 Problems with refrigerant circuit

♦ Possible complaints about refrigerant circuit ⇒ page 97
5.1 Possible complaints about refrigerant

circuit
♦ Test requirements ⇒ page 97
♦ Possible complaints ⇒ page 97
5.1.1 Test requirements:

• Electrical system, vacuum system and air duct fault-finding
has not revealed any faults ⇒ Vehicle diagnostic tester ( „self-
diagnosis“ or „guided fault-finding“ function for air 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 .
5.1.2 Possible complaints
Note
♦ For all complaints marked *, refer to ⇒ page 103 „Checking

pressures“.
♦ If problems are only encountered at one evaporator on vehi‐
cles fitted with two evaporators, also check the pressures in
♦ Heed the test conditions ⇒ page 97 .
♦ Total cooling system failure *

♦ Insufficient cooling output at all vehicle or engine speeds.*
♦ No cooling or insufficient cooling after driving a few miles *
♦ No or insufficient cooling at one or via both evaporators (on
vehicles with two air conditioner units). *
♦ 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) *
Other possible problems:
Air conditioner compressor noise
– Re-tighten the bolts for the air conditioner compressor and the
compressor holder using a torque wrench.
– Check routing of refrigerant pipes; they must not touch other
components and must not be subject to strain (align if neces‐
sary).
5. Problems with refrigerant circuit 97

Noise (refrigerant hammer) occurring immediately after switching

on the air conditioner and/or when cornering or braking
– Discharge, evacuate and re-charge refrigerant circuit (too
much refrigerant in circuit).
Note
Too much refrigerant oil in the circuit may also result in this prob‐
lem (no adjustment of refrigerant oil quantity, for example, on
replacing 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 condensate drain; it must not be
crushed or kinked.
– Check the condensate 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 Connecting air conditioner service

station
♦ Air conditioner service station connection on vehicles with a
connection on the low and high-pressure end of the refrigerant
circuit ⇒ page 99 .
♦ Air conditioner service station connection on vehicles with no
connection on the low-pressure end of the refrigerant circuit
⇒ page 99 .
6.1 Connecting air conditioner service sta‐

tion on vehicles with a connection on the
low and high-pressure end of the refrig‐
erant circuit
Connecting air conditioner service station for measuring and test‐
ing
– 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).
charging hoses (only necessary if there is air in the charging
hoses).
– Unscrew the sealing caps from the service connections (with
valve).
– Connect up the air conditioner service station via the service
connections with quick-release coupling adapters to the vehi‐
cle refrigerant circuit.
– 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 the intended tests and measurements.
6.2 Connecting air conditioner service sta‐

tion on vehicles with no connection on
the low-pressure end of the refrigerant
circuit
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
6. Connecting air conditioner service station 99

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;
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.
♦ Connecting air conditioner service station to refrigerant circuit

with adapter set for refrigerant circuit -V.A.G 1786-
⇒ page 100
♦ Connecting air conditioner service station to refrigerant circuit
with adapter V.A.G 1785/10 ⇒ page 101
♦ Connecting air conditioner service station for measuring and
testing ⇒ page 101

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 insert (standard for con‐
nection with valve for low-pressure switch for air conditioning
system -F73- and also gradually introduced as of 10.94 at the
air conditioner compressor).
♦ Instead of adapter with union nut -V.A.G 1786/1- , you can also
use adapter -V.A.G 1785/10- (remove valve from adapter -
V.A.G 1785/10- or install valve opener in filler hose).


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

the filler hose used (specific to manufacturer).
♦ The quick-release coupling adapter is not required for con‐
nection on the low-pressure side of Audi vehicles.
♦ Screw filler hose -E- (to air conditioner service station) onto
adapter - V.A.G 1785/10- .
Note
To minimise the amount of air and moisture 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.

tion for measuring and testing
– 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).
charging hoses (only necessary if there is air in the charging
hoses).
6. Connecting air conditioner service station 101

– 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 up the air conditioner service station via the service
connections with quick-release coupling adapters to the vehi‐
cle refrigerant circuit.
– 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 the intended tests and measurements.

7 Checking pressures
♦ Checking the pressures in the refrigerant circuit (with the air
conditioner service station) with the ignition switched off
⇒ page 103
♦ Checking pressures on vehicles with a restrictor and reservoir
(with internally regulated air conditioner compressor)
⇒ page 108
♦ Checking pressures on vehicles with an expansion valve and
receiver (with internally regulated air conditioner compressor)
⇒ page 113
♦ Checking pressures on vehicles with restrictor, reservoir and
air conditioner compressor regulating valve -N280- (externally
regulated air conditioner compressor) ⇒ page 118
♦ Checking pressures on vehicles with expansion valve, receiv‐
er and air conditioner compressor regulating valve -N280-
(externally regulated air conditioner compressor)
⇒ page 126
7.1 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 measure‐
ment and testing ⇒ Heating, air conditioning; Rep. gr. 87 or
⇒ Air conditioning; Rep. gr. 87 (vehicle-specific workshop
manual).
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 air con‐
ditioner compressor control. The evaporator is excessively cooled
and ices up. An iced-up evaporator may cause the following prob‐
lems:
♦ Repeated or sporadic failure of the air conditioner (no cooling/
heating output) after a lengthy journey; operation of the air
conditioner soon returns to normal after switching off the en‐
gine
♦ Misting up of the windows on the inside after a long journey;
the windows are initially not cleared even by pressing the De-
7. Checking pressures 103

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 or ⇒ Air
– On vehicles with no evaporator output temperature sender -
G263- use the footwell vent temperature sender -G192- for
example to check the output temperature in the settings: "Lo
temperature" for driver and front passenger side, 4 or 5 bars
for the fresh air blower speed, air outlet to the footwell and
fresh-air mode under the usage conditions described by the
customer. If the measured value of the sender is too low (at
ambient temperature 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.
♦ Test requirements ⇒ page 104 .
♦ Checking pressures ⇒ page 106 .
♦ Continuation of testing depending on design of refrigerant cir‐
cuit ⇒ page 108
7.1.1 Test requirements

• Radiator and condenser clean (clean if necessary)
• Thermal insulation at expansion valve OK and properly instal‐
led.*
• Poly V-belt OK and properly tensioned / belts for air condi‐
tioner compressor and alternator OK and properly tensioned.*
• All air ducts, covers and seals OK and properly installed.
• 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 ⇒
• 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;
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* ⇒
• Engine at operating temperature
• Vehicle not exposed to sunlight ⇒ Heating, air conditioning;
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 on vehicles with two air conditioner
units).
Settings on heater controls:
– Press A/C button and "Rec" or recirculated air button.
– Turn the rotary temperature control towards the „cold“ stop.
– Set rotary fresh-air blower control to „4“.
Subsequently, the following system test requirements should be
met:
• 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 ve‐
hicles 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 safeguard
(if fitted) not tripped).*

Note
Depending on the engine, the air conditioner compressor is driven

by different components (belt or drive shaft). To protect these
components and the engine, the pulley or the air conditioner com‐
pressor drive unit is fitted with an overload safeguard which is
tripped if the air conditioner compressor is not operating smoothly
7.1.2 Checking pressures

– Connect air conditioner service station ⇒ page 99 .
– Read pressures off pressure gauges; there are two possible
results:
♦ The pressure in the refrigerant circuit is lower than indicated
in the table.
♦ The pressure in the refrigerant circuit corresponds to that in‐
dicated in the table or is higher.
Ambient temperature (in de‐ Pressure in refrigerant circuit in
grees centigrade) bar
+15 °C 3,9
+20 °C 4,7
+25 °C 5,6
+30 °C 6,7
+35 °C 7,8
+40 °C 9,1
+45 °C 10,5
Note
♦ The temperature of the refrigerant circuit components should

be equal to ambient temperature (the pressure will deviate
from the values in the table if individual components of the
refrigerant circuit are warmer or colder).
♦ At absolute pressure, 0 bar corresponds to an absolute vac‐
uum. The 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).
♦ On vehicles with a high-pressure sender -G65- or refrigerant
pressure and temperature sender -G395- for which the meas‐
ured pressure is displayed in the measured value block, the
pressure measured should coincide with the values in the ta‐
ble ⇒ Vehicle diagnostic tester ( „self-diagnosis“ or „guided
fault-finding“ function for air conditioner) and ⇒ Heating, air
♦ Pressure may be given in various units: 1 MPa (megapascal)
corresponds to 10 bar gauge pressure or 145 psi; 1 bar ab‐
solute pressure corresponds to 0 bar gauge pressure, which
is roughly equivalent to atmospheric pressure.

The pressure in the refrigerant circuit is lower than indicated in

the table.
Not enough refrigerant in circuit
– Determine refrigerant circuit leaks ⇒ page 87 .
– Check the pressure relief valve.
If the pressure relief valve has responded:
– Check actuation of the radiator fans.
– Check for constricted refrigerant pipe 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 (flush with refriger‐
ant R134a ⇒ page 59 or blow out with compressed air and
nitrogen ⇒ page 55 ).
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 con‐
ditioning; Rep. gr. 87 or ⇒ Air conditioning; Rep. gr. 87 (vehicle-
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 actuation of the air conditioner compressor regulating
valve -N280- ⇒ Vehicle diagnostic tester ( „self-diagnosis“ or
„guided fault-finding“ function for air conditioner) and ⇒ Heat‐
Note
♦ If low-pressure switch has been removed to connect air con‐

ditioner service station, jumper electrical connections in rele‐
vant connector for pressure measurement.
♦ 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

♦ Continuation of testing depending on design of refrigerant cir‐

cuit ⇒ page 108
7.1.3 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 108
♦ Checking pressures on vehicles with an expansion valve and
receiver (with internally regulated air conditioner compressor)
⇒ page 113
♦ Checking pressures on vehicles with restrictor, reservoir and
air conditioner compressor regulating valve -N280- (with ex‐
ternally regulated air conditioner compressor) ⇒ page 118
♦ Checking pressures on vehicles with expansion valve, receiv‐
er and air conditioner compressor regulating valve -N280-
(with externally regulated air conditioner compressor)
⇒ page 126
7.2 Checking pressures on vehicles with a

restrictor and reservoir (with internally
regulated air conditioner compressor)
Note
♦ Connect air conditioner service station ⇒ page 99 .

♦ Observe test requirements ⇒ page 103 .
– Check the pressures in the refrigerant circuit (with the air con‐
ditioner service station) with the ignition switched off
⇒ page 103 .
The pressures with the ignition switched off correspond to the
specifications.
– Start the engine.
– Set engine speed to 2000 rpm.
– Observe the pressure reading (e.g. pressure gauge) of the air
Note
♦ Switching pressures for refrigerant circuit switches are vehi‐

cle-specific.
♦ The 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 end and an inaccessible connec‐
tion at the air conditioner compressor or reservoir (measure‐
ment accuracy). Only applies to certain vehicles ⇒ Heating,
♦ Specifications for pressures in refrigerant circuit ⇒ page 109

7.2.1 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 pressure (measured at connection with valve at air con‐
ditioner compressor or reservoir) in bar
C - Permissible tolerance range
D - Low pressure (measured at connection with valve for low-
pressure switch or at service connection) in bar
E - Permissible tolerance range
Possible deviation from specification Possible causes of fault Fault elimination

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

• Low pressure in line with value in
graph
tained

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

with refrigerant R134a ⇒ page 59 or blow out with compressed
air and nitrogen ⇒ page 55 ).


• 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 or ⇒
• low pressure does not decrease ♦ The air conditioner compressor Air conditioning; Rep. gr. 87 .
or only slightly. is not driven.
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 59 or blow out with com‐
„low-pressure end“ service pressed air and nitrogen
connection and the air condi‐ ⇒ page 55 ).
tioner compressor).
– Renew hose or pipe if kinked or
constricted.
♦ Air conditioner compressor de‐ – Replace the air conditioner com‐
fective. pressor.

• High pressure increases above Constriction or obstruction in re‐ – Run hand over refrigerant circuit
specification frigerant circuit to check for differences in tem‐
perature
• Low pressure quickly drops to
value in graph or below • If difference in temperature is
• Required cooling output is not at‐ found at one component:
tained – Renew hose or pipe if kinked or
constricted.
– In the event of clogging, clean

refrigerant circuit (flush with re‐
frigerant R134a ⇒ page 59 or
blow out with compressed air
and nitrogen ⇒ page 55 ).
• If no fault is found:
– Clean the refrigerant circuit
(flush with refrigerant R134a
⇒ page 59 or blow out with com‐
pressed air and nitrogen
⇒ page 55 ).
• High and low pressure normal at Moisture in refrigerant circuit – Check and if necessary replace
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 the refrigerant circuit
graph or below (flush with refrigerant R134a
⇒ page 59 or blow out with com‐
• Required cooling output is no lon‐ pressed air and nitrogen
ger attained ⇒ page 55 ).
• 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 replace 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
air and nitrogen ⇒ page 55 ) when this problem occurs. Nor‐
mally, there is only a small quantity of moisture in the system
which can be removed by lengthy evacuation.

• High pressure normal Air conditioner compressor defective. – Clean the refrigerant
circuit (flush with re‐
• Low pressure too low (see graph) frigerant R134a
• Required cooling output is at‐ ⇒ page 59 or blow
tained out with compressed
air and nitrogen
⇒ page 55 ).
– Replace the air con‐

ditioner compressor.
Note
♦ Heed the following in the event of the fault „High pressure nor‐
mal, low pressure too low“: This fault may result in the evap‐
orator icing up or the low-pressure switch for air conditioning
system -F73- switching off the air conditioner compressor al‐
though the quantity of refrigerant in the circuit is OK.
♦ On the Audi 100, Audi A6 (up to and including Model Year
1997) and the Audi V8, this fault may result in the air condi‐
tioner compressor being shut off by the operating and display
unit (if the temperature at the fresh-air blower drops below -3
°C) ⇒ Heating, air conditioning; Rep. gr. 87 .


• 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
– Replace the air con‐
ditioner compressor.
• The quantity of re‐

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

• High and low pressure normal Too much refrigerant oil in the circuit. – Discharge refriger‐
ant circuit.
tained – Clean refrigerant
circuit (flush with re‐
frigerant R134a
⇒ page 59 or blow
out with com‐
pressed air and ni‐
trogen ⇒ page 55 ).
• High and low pressure normal
• Air conditioner compressor noise
(particularly after switch-on)
• Required cooling output is at‐
tained
Note
♦ Overfilling with refrigerant oil may occur if, for example, the air
conditioner compressor has been replaced without adjusting
the quantity of refrigerant oil.
♦ If there is too much refrigerant oil in the circuit, drain the air
conditioner compressor and replace the reservoir. After clean‐
ing the refrigerant circuit (flush with refrigerant R134a
⇒ page 59 or blow out with compressed air and nitrogen
⇒ page 55 ), add the correct amount of refrigerant oil to the

7.3 Checking pressures on vehicles with an

expansion valve and receiver (with in‐
ternally regulated air conditioner com‐
pressor)
Note
♦ Connecting air conditioner service station ⇒ page 99

⇒ page 103 .
specifications.
– Set the engine speed to 2000 rpm.
Note
♦ Switching pressures and design of refrigerant circuit switches

are vehicle-specific.
♦ The pressures must be measured at the service connections;
the fitting locations of these connections are vehicle-specific

ant circuit
High-pressure side:
up to max. 20 bar
Low-pressure end:
to value in graph
A - High pressure in bar
B - Low pressure in bar

Possible deviation from Possible causes of fault Fault elimination

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

substantially less than the specified ca‐
• Low pressure in line with pacity.
value in graph
– Localise leak with leak detector and
• Required cooling output eliminate
is not attained
– Repeat test.
Note
If no fault can be found and air conditioner operation is not OK

when the test is repeated, clean the refrigerant circuit (flush with
refrigerant R134a ⇒ page 59 or blow out with compressed air and
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 or
pressure ♦ The air condi‐ ⇒ Air conditioning;
with the en‐ tioner compres‐ Rep. gr. 87
gine stop‐ sor is not driven.
ped,
• low pres‐
sure does
not de‐
crease or
only slightly.
• Required
cooling out‐
put is not at‐
tained


tion from speci‐ fault
fication
♦ Constriction or – Clean the refrigerant
blockage in the circuit (flush with re‐
refrigerant circuit frigerant R134a
(e.g. in the refrig‐ ⇒ page 59 or blow out
erant pipe be‐ with compressed air
tween the „low- and nitrogen
pressure end“ ⇒ page 55 ).
service connec‐
tion and the air – Replace hose or pipe
conditioner com‐ if kinked or constric‐
pressor). ted.
♦ Air conditioner – Replace the air con‐

compressor de‐ ditioner compressor.
fective.

specification
• High pressure increases ♦ Constriction or obstruction in refrig‐ – Run hand over refrigerant circuit to
above specification erant circuit check for differences in tempera‐
ture
• Low pressure quickly ♦ Expansion valve defective
drops to value in graph • If difference in temperature is found
or below at one component:
• Required cooling output – Renew hose or pipe if kinked or
is not attained constricted.
– In the event of clogging, clean the

refrigerant circuit (flush with refrig‐
erant R134a ⇒ page 59 or blow out
with compressed air and nitrogen
⇒ page 55 and replace the expan‐
sion valve if applicable).
– Clean the refrigerant circuit (flush
with refrigerant R134a ⇒ page 59 or
blow out with compressed air and
nitrogen ⇒ page 55 and replace the
expansion valve if applicable).
– Repeat test.
Note
If operation is not OK after cleaning the refrigerant circuit (flush

air and nitrogen ⇒ page 55 ), the expansion valve must be re‐
placed.


specification
• High and low pressure ♦ Expansion valve defective – Replace 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 the refrigerant circuit (flush
• Required cooling output with refrigerant R134a ⇒ page 59
is no longer attained or blow out with compressed air
• High and low pressure
normal at first
• After lengthy operating
period, low pressure
drops excessively
(evaporator ices up)
Note

at least 3 hours.
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 substantially greater than
the specified capacity.
– Repeat test.

Note
If operation of the air conditioning system is not OK when the test

is repeated, re-fit the old expansion valve and clean the refriger‐
ant circuit (flush with refrigerant R134a ⇒ page 59 or blow out with
compressed air and nitrogen ⇒ page 55 ). Then replace the air
conditioner compressor and receiver.

tion
• High pressure only increases Air conditioner compressor de‐ – Clean the refrigerant circuit (flush
slightly above pressure with fective. with refrigerant R134a ⇒ page 59
engine stopped or blow out with compressed air
• Low pressure only drops slight‐
ly – Replace the air conditioner com‐
• Required cooling output is not pressor and receiver.
attained

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

test is repeated, re-fit the old expansion valve and clean the
refrigerant circuit (flush with refrigerant R134a ⇒ page 59 or
blow out with compressed air and nitrogen ⇒ page 55 ). Then
replace the air conditioner compressor and receiver.
♦ With this fault, the evaporator may ice up although the quantity
of refrigerant in the circuit is OK.

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 59 or
blow out with compressed air and


tion
• High and low pressure normal
noise (particularly after switch-
on)
• Required cooling output is at‐
tained
Note
conditioner compressor and replace the receiver. After clean‐
7.4 Checking pressures on vehicles with re‐

strictor, reservoir and air conditioner
compressor regulating valve -N280-
(with externally regulated air conditioner
compressor)
Note
♦ Connecting air conditioner service station ⇒ page 99

⇒ page 103 .
specifications.
Note
♦ The switching pressures for actuation of -N280- and the radi‐

ator fans -V7- are vehicle-specific.


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

Low-pressure end:
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

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

high ambient temperature and high fresh-air blower speed at
low engine speed), the air conditioner compressor cannot in‐
itially set the pressure on the low-pressure end to the value
-C- given in the graph (e.g. for a certain time after switching
on the air conditioner). The air conditioner compressor is ac‐
tuated with the maximum specified control current, however
the delivery volume of the air conditioner compressor is no
longer sufficient under these ambient conditions and at this
engine speed to reduce the pressure on the low-pressure end
to the value in the graph. One way of checking the control ac‐
tion of the air conditioner compressor under these conditions
is to 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. 87 or ⇒ Air condi‐
♦ Under unfavourable conditions (very high ambient tempera‐
tures, high humidity), the pressure on the high-pressure end
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 operating and display unit, Cli‐
matronic 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
ditioning system -E87- or the operating and display unit, Cli‐
matronic control unit -J255- ⇒ Vehicle diagnostic tester ( „self-
diagnosis“ or „guided fault-finding“ function for air conditioner)
♦ The low pressure settles as a function of the control current
for the air conditioner compressor regulating valve -N280-
within the air conditioner compressor output range in the tol‐
erance band.
tures, high humidity), the air conditioner compressor output
may not always be sufficient to attain the specified value.
♦ If the compressor capacity utilisation is greater than 90 %, the
pressure on the low-pressure end may be in excess of the
tolerance range „C“ shown in the graph (the compressor out‐
put no longer suffices).
♦ The specified operating current for the regulating valve must
be greater than 0.3 A to ensure reliable actuation of the regu‐
lating valve.
♦ At absolute pressure, „0 bar“ corresponds to an absolute vac‐
uum. 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“).
♦ 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. 87 or ⇒ Air


specification
• High pressure remains ♦ Actuation of air conditioner com‐ – Check actuation of -N280- .
constant or only increa‐ pressor regulating valve -N280-
ses slightly (above pres‐ not OK – Localise leak with leak detector and
sure with engine stop‐ eliminate
ped) ♦ Not enough refrigerant in circuit
• Low pressure quickly
drops to value in graph or
below
• Required cooling output
is not attained

• Low pressure too low
(see graph)
is not attained

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

air and nitrogen ⇒ page 55 ).
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 or ⇒ Air conditioning;
Rep. gr. 87
• low pressure does not de‐ ♦ The air conditioner compressor is
crease or only slightly. not driven.
• Required cooling output is
not attained
♦ Constriction or blockage in the re‐ – Clean the refrigerant circuit (flush

frigerant circuit (e.g. in the refrig‐ with refrigerant R134a ⇒ page 59 or
erant pipe between the „low- blow out with compressed air and ni‐
pressure end“ service connection trogen ⇒ page 55 ).
and the air conditioner compres‐
sor). – Replace hose or pipe if kinked or
constricted.
♦ Air conditioner compressor de‐ – Replace the air conditioner com‐
fective. pressor.


ification
• High pressure increases ♦ Actuation of air conditioner com‐ – Check actuation of -N280- .
above specification pressor regulating valve -N280-
not OK – Run hand over refrigerant circuit to
• Low pressure quickly check for differences in temperature
drops to value in graph or ♦ Constriction or obstruction in re‐
below frigerant circuit • If difference in temperature is found
• Required cooling output is at one component:
not attained – Replace hose or pipe if kinked or
constricted.
– Flush the refrigerant circuit with com‐

pressed air and nitrogen if clogged.
– Clean refrigerant circuit (flush with
refrigerant R134a ⇒ page 59 or blow
out with compressed air and nitrogen
⇒ page 55 ).

ification
• High and low pressure ♦ Actuation of air conditioner com‐ – Check actuation of -N280- .
normal at first, after some pressor regulating valve -N280-
time high pressure increa‐ not OK – Replace reservoir (with dryer) and
ses above specification evacuate refrigerant circuit for at
and ♦ Moisture in refrigerant circuit least 3 hours (see note)
• Low pressure drops to val‐ – Clean refrigerant circuit (flush with
ue in graph or below refrigerant R134a ⇒ page 59 or blow
• Required cooling output is out with compressed air and nitrogen
no longer attained ⇒ page 55 ).
• High and low pressure

normal at first
• After lengthy operating pe‐
riod, low pressure drops
excessively (evaporator
ices up)

Note

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“ func‐
tion for air conditioner) and ⇒ Heating, air conditioning; Rep.
workshop manual).

ification
• High pressure normal ♦ Actuation of air conditioner com‐ – Check actuation of -N280- .
pressor regulating valve -N280-
• Low pressure too low (see not OK – Clean refrigerant circuit (flush with
graph) refrigerant R134a ⇒ page 59 or
♦ Air conditioner compressor de‐ blow out with compressed air and
• Required cooling output is fective.
attained nitrogen ⇒ page 55 ).
– Replace the air conditioner com‐

pressor.
Note
Heed the following in the event of the fault „High pressure normal,
low pressure too low“: With this fault, the evaporator may ice up
although the quantity of refrigerant in the circuit is OK. Check the
measured values of the evaporator output temperature sender -
G263- and actuation of the air conditioner compressor regulating
valve -N280- . If the measured value of the evaporator output
temperature sender -G263- is incorrect, the evaporator may ice
up or the cooling output is not attained ⇒ Vehicle diagnostic tester
( „self-diagnosis“ or „guided fault-finding“ function for air condi‐
tioner) and ⇒ Heating, air conditioning; Rep. gr. 87 or ⇒ Air


ification
• High pressure normal or ♦ Actuation of air conditioner compressor – Check actuation of -N280- .
too high regulating valve -N280- not OK
– Extract refrigerant from refrig‐
• Low pressure too high ♦ Too much refrigerant in the circuit. erant circuit.
(see graph)
• Air conditioner compres‐ • If quantity of refrigerant ex‐
sor noise (particularly after tracted roughly corresponds
switch-on) to specified capacity:
• Required cooling output is – Replace the air conditioner

not attained compressor.
• The quantity of refrigerant ex‐

tracted is substantially greater
than the specified capacity.
– 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 and low pressure – Clean the refrigerant circuit

normal. (flush with refrigerant R134a
⇒ page 59 or blow out with
• Air conditioner compres‐ compressed air and nitrogen
sor noise (particularly after ⇒ page 55 ).
switch-on).
• The required cooling out‐
put is attained.
Note
conditioner compressor and replace the reservoir. After clean‐

7.5 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 99 .

♦ Observe test requirements ⇒ page 103 .
♦ 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 pipe connection between the prob‐
lematic evaporator and the outgoing pipe connection at the
refrigerant pipe 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, replace the
expansion valve upstream of the problematic evaporator ⇒
⇒ page 103 .
specifications.
Note
♦ The switching pressures for actuation of the air conditioner

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

ant circuit
High-pressure side:
up to max. 20 bar

Low-pressure side:
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 %).

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

high ambient temperature and high fresh-air blower speed at
low engine speed), the air conditioner compressor cannot in‐
itially set the pressure on the low-pressure end to the value
-C- given in the graph (e.g. for a certain time after switching
on the air conditioner). The air conditioner compressor is ac‐
tuated with the maximum specified control current, however
the delivery volume of the air conditioner compressor is no
longer sufficient under these ambient conditions and at this
engine speed to reduce the pressure on the low-pressure end
to the value in the graph. One way of checking the control ac‐
tion of the air conditioner compressor under these conditions
is to 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)
tures, high humidity), the pressure on the high-pressure end
may increase up to max. 29 bar.
♦ The control current -B- is displayed in the measured value
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- is displayed in the measured value block of the
operating and display unit for Climatronic air conditioning sys‐
tem -E87- or the operating and display unit, Climatronic control
unit -J255- .
♦ The low pressure settles as a function of the control current
for the air conditioner compressor regulating valve -N280- and
the control characteristic of the expansion valve within the air
conditioner compressor output range in the tolerance band.
tures, high humidity), the air conditioner compressor output
may not always be sufficient to attain the specified value.
♦ If the compressor capacity utilisation is greater than 90 %, the
pressure on the low-pressure end may be in excess of the
tolerance range „C“ shown in the graph (the compressor out‐
put no longer suffices).
♦ The specified operating current for the air conditioner com‐
pressor regulating valve -N280- must be greater than 0.3 A to
ensure reliable valve actuation.
♦ In the „maximum cooling output“ setting, the control current for
the air conditioner compressor regulating valve -N280- is regu‐
lated to approx. 0.65 A (up to 0.85 A). This measured value is
vehicle-specific and displayed in the measured value block.
♦ At absolute pressure, 0 bar corresponds to an absolute vac‐
uum. 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) ⇒ Vehicle diagnostic tester ( „self-diagnosis“ or „gui‐
ded fault-finding“ function for air conditioner) and ⇒ Heating,

Possible deviation from speci‐ Possible causes of fault Fault elimination

fication
• High pressure remains con‐ ♦ Actuation of air conditioner compres‐ – Check actuation of -N280-
stant or only increases sor regulating valve -N280- not OK
slightly (above pressure – Extract refrigerant from re‐
with engine stopped) ♦ Not enough refrigerant in circuit frigerant circuit.
• Low pressure quickly drops ♦ Expansion valve defective • If quantity of refrigerant ex‐
to value in graph or below tracted is substantially less
• Required cooling output is than specified capacity:
not attained
• High pressure normal – Localise leak with leak de‐

tector and eliminate
• Low pressure in line with
value in graph – Re-charge refrigerant circuit.
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.
not attained – Re-charge refrigerant circuit.
– Repeat test.
Note
♦ If no fault is found for this problem, clean refrigerant circuit

(flush with refrigerant R134a ⇒ page 59 or blow out with com‐
pressed air and nitrogen ⇒ page 55 ).
♦ 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 replacing 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 59 or blow out with compressed air
and nitrogen ⇒ page 55 ). Then replace the air conditioner
compressor and receiver.
♦ If the expansion valve is defective (permanently closed or
does not open sufficiently), -N280- is actuated to maximum
output and the low pressure drops to the value in the graph or
below (the air conditioner compressor draws off refrigerant
from the low-pressure end). 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 due to the absence of energy conversion ⇒ Vehicle
workshop manual).


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 or
stopped, ⇒ Air conditioning;
♦ The air condition‐ Rep. gr. 87
• low pressure er compressor is
does not de‐ not driven.
crease or on‐
ly slightly.
• Required
cooling out‐
put is not at‐
tained
♦ Constriction or – Clean the refriger‐

blockage in the ant circuit (flush
refrigerant circuit with refrigerant
(e.g. in the refrig‐ R134a ⇒ page 59
erant pipe be‐ or blow out with
tween the „low- compressed air and
pressure end“ nitrogen
service connec‐ ⇒ page 55 ).
tion and the air
conditioner com‐ – Replace hose or
pressor). pipe if kinked or
constricted.
♦ Air conditioner – Replace the air
compressor de‐ conditioner com‐
fective. pressor.


ification
• High pressure increases ♦ Actuation of air conditioner com‐ – Check actuation of -N280- .
above specification pressor regulating valve -N280-
not OK – Run hand over refrigerant circuit to
• Low pressure quickly check for differences in temperature
drops to value in graph ♦ Constriction or obstruction in re‐
frigerant circuit • If a difference in temperature is
not attained ♦ Expansion valve defective found at one component:
– Replace hose or pipe if kinked or
constricted.
– In the event of clogging, clean the

refrigerant circuit (flush with refriger‐
ant R134a ⇒ page 59 or blow out with
compressed air and nitrogen
⇒ page 55 ).
– Repeat test.
– Clean refrigerant circuit (flush with
refrigerant R134a ⇒ page 59 or blow
out with compressed air and nitrogen
⇒ page 55 ).
– Repeat the test, if the function is not

OK:
– Renew expansion valve and receiv‐

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

the test is repeated, renew expansion valve and receiver.
does not open sufficiently), the air conditioner compressor
regulating valve -N280- is actuated to maximum output and
the low pressure drops to the value in the graph or below (the
air conditioner compressor draws off refrigerant from the low-
pressure end). 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 due
to the absence of energy conversion ⇒ Vehicle diagnostic
tester ( „self-diagnosis“ or „guided fault-finding“ function for air
conditioner) and ⇒ Heating, air conditioning; Rep. gr. 87 or
manual).


fication
• High and low pressure nor‐ ♦ Actuation of air conditioner compres‐ – Check actuation of -N280- .
mal at first sor regulating valve -N280- not OK
– Clean refrigerant circuit
• After some time, high pres‐ ♦ Moisture in refrigerant circuit (flush with refrigerant R134a
sure increases above spec‐ ⇒ page 59 or blow out with
ification and compressed air and nitrogen
• low pressure drops to value ⇒ page 55 ).
in graph or below
no longer attained
• 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.
Note

up), it is sufficient to replace the dryer in the receiver (adjust
quantity of refrigerant oil). The refrigerant circuit is then to be
evacuated 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“ func‐
tion for air conditioner) and ⇒ Heating, air conditioning; Rep.
workshop manual).


fication
• High pressure normal ♦ Actuation of air conditioner compres‐ – Check actuation of -N280- .
sor regulating valve -N280- not OK
• Low pressure too low (see – Clean refrigerant circuit
graph) ♦ Expansion valve or air conditioner (flush with refrigerant R134a
compressor defective. ⇒ page 59 or blow out with
attained ♦ Air conditioner compressor defective. compressed air and nitrogen
⇒ page 55 ) (not always nec‐
essary, refer to notes).
– Renew expansion valve and

receiver.
– Repeat the test, if the func‐

tion is not OK:
– Replace the air conditioner

compressor.
– Repeat test.
Note
♦ Heed the following in the event of the fault „High pressure nor‐
mal, low pressure too low“: With this fault, the evaporator may
ice up although the quantity 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 (flush
air and nitrogen ⇒ page 55 ). It is sufficient in this case to re‐
place the air conditioner compressor (heed quantity of refrig‐
erant oil in air conditioner compressor).
from the low-pressure end). As refrigerant cannot however
flow via expansion valve, cooling output is not attained and
high pressure may either not increase or only slightly due to
the absence of energy conversion.
♦ Check the measured values of the evaporator output temper‐
ature sender -G263- and actuation of -N280- . If the measured
value of the evaporator output temperature sender -G263- is
incorrect, the evaporator may ice up or the cooling output is
not attained ⇒ Vehicle diagnostic tester ( „self-diagnosis“ or
„guided fault-finding“ function for air conditioner) and ⇒ Heat‐


fication
• High pressure normal or too ♦ Actuation of air conditioner compres‐ – Check actuation of -N280- .
high sor regulating valve -N280- not OK
– Extract refrigerant from re‐
• Low pressure too high (see ♦ Too much refrigerant in the circuit. frigerant circuit.
graph)
♦ Expansion valve defective
• Air conditioner compressor • The quantity of refrigerant
noise (particularly after ♦ Air conditioner compressor defective. extracted roughly corre‐
switch-on) sponds to the actual capaci‐
ty.
attained – Renew expansion valve and
receiver.
– Repeat the test, if the func‐

tion is not OK:
– Replace the air conditioner

compressor.
• If quantity of refrigerant ex‐

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

the circuit. Overfilling with refrigerant oil may occur if, for ex‐
ample, the air conditioner compressor has been replaced
without adjusting the quantity of refrigerant oil.
from the low-pressure end). 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 due to the absence of energy conversion ⇒ Vehicle
workshop manual).

fication
• High and low pressure nor‐ ♦ Actuation of air conditioner compres‐ – Check actuation of -N280- .
mal sor regulating valve -N280- not OK
• Required cooling output is ♦ Too much refrigerant in the circuit.
attained – Clean refrigerant circuit
♦ Expansion valve defective
(flush with refrigerant R134a
⇒ page 59 or blow out with
compressed air and nitrogen
⇒ page 55 ).


fication
• High and low pressure nor‐ – Add the correct quantity of
mal refrigerant oil to the circuit
(refer to note).
noise (particularly after – Re-charge refrigerant circuit.
switch-on)
• Required cooling output is – Repeat the test, if the func‐
attained tion is not OK:
– Renew expansion valve.
– Repeat test.
Note
♦ If the expansion valve is defective (permanently open), the
evaporator temperature is no longer regulated such that only
refrigerant in gas form exits from the evaporator. Under certain
usage conditions, liquid droplets may then be drawn in by the
air conditioner compressor and cause noise (liquid cannot be
compressed).

8 Renewing components of refrigerant

circuit
♦ Replacing components ⇒ page 136 .
8.1 Renewing components

• All components of the refrigerant circuit submitted for quality
observation are always to be sealed (use the original sealing
caps of the replacement part).
• Replacement air conditioner compressors, reservoirs, receiv‐
ers, evaporators and condensers have so far been filled with
nitrogen gas. This charge is being gradually discontinued/the
pressure of the nitrogen charge is now so low that the escape
of gas is no longer preceptible on initial opening.
• On vehicles fitted with an air conditioner compressor with no
magnetic clutch, the engine is only to be started following
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 dryer cartridge or components with desiccant bag (reser‐
voir, receiver) are always to be replaced after cleaning the
refrigerant circuit (flushing with refrigerant R134a ⇒ page 59
or blowing out with compressed air and nitrogen ⇒ page 55 );
in doing so, leave sealed as long as possible to minimise the
absorption of moisture.
♦ The dryer cartridge or components with desiccant bag (reser‐
voir, receiver) are to be replaced if required for certain repair
operations or if the refrigerant circuit has been open for a
lengthy period and moisture has ingressed (e.g. following an
accident) ⇒ page 138 .
♦ The period of time for which a refrigerant circuit may be left
open without having to replace a component with desiccant
bag (reservoir, receiver) is largely governed by ambient influ‐
ences. Given a high ambient temperature and a high humidity
level or if the vehicle has been standing in the open for exam‐
ple or driven (in wet, foggy weather conditions), the period will
be considerably shorter than for a vehicle which has been
standing 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 replace components with desiccant bag
⇒ page 138 .
♦ Seal open connections and pipes (to prevent absorption of
moisture).
♦ Always renew restrictor.
Caution
♦ Contaminated refrigerant oils must be disposed of as used

oils of unknown origin ⇒ Audi-ServiceNet, HSO Environ‐
mental Protection .
♦ Leaking or damaged components (except air conditioner com‐

pressor, reservoir or receiver) ⇒ page 138
♦ Leaking or damaged components (except air conditioner com‐
pressor, reservoir or receiver) ⇒ page 139
♦ Replacing air conditioner compressor without the need for re‐
frigerant circuit cleaning ⇒ page 140 .
♦ Replacing air conditioner compressor on account of leakage
or internal damage ⇒ page 141
♦ Renewing receiver or reservoir and restrictor after cleaning
refrigerant circuit ⇒ page 141
♦ Replacing receiver or reservoir without the need for refrigerant
circuit cleaning ⇒ page 143 .
8. Renewing components of refrigerant circuit 137

♦ Replacing dryer cartridge/desiccant bag without the need for

refrigerant circuit cleaning ⇒ page 143
8.1.1 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).
– Remove defective component.

– Remove the air conditioner compressor.*

– 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,
♦ On the „Denso“ or „Nippondenso“ air conditioner compressor,
the oil drain plug -D- is fitted with a sealing ring -E- for example;
always replace ⇒ 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; always
replace ⇒ 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 Pro‐
tection ).
♦ 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 164 .*
♦ Use different refrigerant oils and quantities for the various air
conditioner compressors ⇒ page 164 .
♦ To ensure air conditioner compressor lubrication on start-up,
at least 80 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 164 .
♦ If dirt has ingressed into the air conditioner compressor with
the refrigerant circuit open (e.g. after an accident), the air con‐
ditioner compressor is to be replaced.
♦ Clean refrigerant circuit (flush with refrigerant R134a
⇒ page 59 or blow out with compressed air or nitrogen
⇒ page 55 ).*
– Renew dryer cartridge, receiver* or reservoir* and restrictor.

– Assemble, evacuate and re-charge refrigerant circuit.
8.1.2 Leaking or damaged components (ex‐

cept air conditioner compressor, reser‐
voir or receiver)
Refrigerant circuit still contains refrigerant (e.g. minor leak)
– Remove the defective component, blow out with compressed
air and collect the refrigerant oil escaping.
– The new component is to be filled with the amount of refriger‐
ant oil blown out (plus 20 cm3 for the evaporator, plus 10
cm3 for the condenser, refrigerant pipes and refrigerant hoses)
as fresh refrigerant oil fill.

Note
Disposal of old refrigerant ⇒ Audi-ServiceNet, HSO Environmen‐

tal Protection .
– Renew restrictor.
– Assemble, evacuate and charge refrigerant circuit.
8.1.3 Replacing air conditioner compressor

without the need for refrigerant circuit
cleaning
Note
Cleaning refrigerant circuit means flushing with refrigerant R134a

⇒ page 59 or blowing out with compressed air or nitrogen
⇒ page 55 .
For example in the case of external damage following an accident

– Drain the refrigerant circuit.
– Remove the air conditioner compressor.
– Remove the oil drain plug from the 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
replace) ⇒ page 138 and ⇒ Electronic parts catalogue .
– To accelerate drainage of the refrigerant oil, crank the air con‐

example.
– Pour the old refrigerant oil out of the air conditioner compres‐
sor (for disposal, refer to ⇒ Audi-ServiceNet, HSO Environ‐
mental Protection ).
– Remove the oil drain plug from the replacement compressor,
pour out the refrigerant oil and only add a quantity of fresh
refrigerant oil equal to the amount poured out of the defective
air conditioner compressor.

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), fill the air con‐
ditioner compressor to be installed with 70 cm3 of refrigerant
oil (use can be made of the oil poured out of the replacement
compressor).
♦ If a greater quantity of refrigerant oil (more than approx. 80
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 144 .
8.1.4 Replacing air conditioner compressor

on account of leakage or internal dam‐
age
For example due to noise from the air conditioner compressor or
no air conditioner compressor output
– Drain the refrigerant circuit.
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
air or nitrogen ⇒ page 55 ) and replace 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 55 .
– Renew dryer cartridge, receiver or reservoir and restrictor.

– Check expansion valve for dirt or corrosion and renew if nec‐
essary
8.1.5 Renewing receiver or reservoir and re‐

strictor after cleaning refrigerant circuit
Note

⇒ page 55 .

For example on account of ingress of moisture (refrigerant circuit

open for lengthy period) or contamination
– Eliminate cause of fault.
– Clean refrigerant circuit (flush with refrigerant R134a
⇒ page 59 or blow out with compressed air or nitrogen
⇒ page 55 ).
– Check expansion valve for dirt or corrosion and renew if nec‐
essary
– Remove the oil drain plug from the 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
replace) ⇒ page 138 and ⇒ Electronic parts catalogue .
– To accelerate drainage of the refrigerant oil, crank the air con‐

example.
– Pour the old refrigerant oil out of the air conditioner compres‐
sor.
Note
Disposal of old refrigerant ⇒ Audi-ServiceNet, HSO Environmen‐

tal Protection .
– 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 164 .
Note
♦ To ensure air conditioner compressor lubrication on start-up,
at least 80 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 144 .
♦ If dirt has ingressed into the air conditioner compressor with
the refrigerant circuit open (e.g. after an accident), the air con‐
ditioner compressor is to be replaced.
♦ 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 55 .
– Renew receiver or reservoir and restrictor.


8.1.6 Replacing receiver or reservoir without

the need for refrigerant circuit cleaning
Note

⇒ page 55 .
For example in the event of accident damage; no refrigerant es‐

caped and no ingress of moisture and dirt into the circuit
– Remove receiver or reservoir.
– 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.
8.1.7 Replacing dryer cartridge/desiccant bag

without the need for refrigerant circuit
cleaning
Note
Cleaning the refrigerant circuit means flushing with refrigerant

R134a ⇒ page 59 or blowing out with compressed air or nitrogen
⇒ page 55 .
For example in the event of a leak; refrigerant has escaped but

no dirt has ingressed into the circuit
– Discharge the refrigerant circuit.
– Replace the dryer cartridge ⇒ Heating, air conditioning; Rep.
workshop manual).
– Assemble, evacuate and charge the refrigerant circuit.

9 Capacities for refrigerant R134a, re‐

frigerant oil and approved refrigerant
oils
♦ Capacities for refrigerant R134a ⇒ page 144
♦ Approved refrigerant oils and refrigerant oil capacities
⇒ page 164
9.1 Capacities for refrigerant R134a
Note
♦ When charging refrigerant circuits on the high-pressure end,

always fill as far as the upper tolerance limit (liquid refrigerant
remains in the charging hoses).
♦ 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
or ⇒ Air conditioning; Rep. gr. 87 (vehicle-specific workshop
manual).
Note
♦ Refrigerant circuits converted from R12 to R134a are to be

filled with the quantity indicated in the Workshop Manual „Air
conditioner with refrigerant R12“. ⇒ Air conditioner with re‐
frigerant R12 (this Workshop Manual is only available in hard‐
copy form).
♦ ⇒ „9.1.1 Capacities for Audi A1 (8X_) 2011 ►“, page 145

♦ ⇒ „9.1.2 Capacities for Audi A2 (8Z_) 2001 ►“, page 145
♦ ⇒ „9.1.3 Capacities for Audi A3 (8L_) 1997 ► and Audi TT (8N_)
1999 ►“, page 146
♦ ⇒ „9.1.4 Capacities for Audi A3 (8P_) 2004 ►“, page 149
♦ ⇒ „9.1.5 Capacities
with respect for Audi
to the TT (8J_)
correctness 2007in►“,
of information page 150
this document. Copyright by AUDI AG.
♦ ⇒ „9.1.6 Capacities for Audi 80 (8A_ / 8C_), Audi Coupé (8B_),

Audi Cabriolet (8G_) ► 2002“, page 150
♦ ⇒ „9.1.7 Capacities for Audi A4 (8D_) 1995 ► “, page 151
♦ ⇒ „9.1.8 Capacities for Audi A4 (8E_) 2001 ►, Audi A4 Cab‐
riolet (8H_) 2003 ►“, page 153
♦ ⇒ „9.1.9 Capacities for Audi A4 (8K_) 2008 ►, Audi A5 Coupé
and Sportback (8T_) 2008 ►, Audi Q5 (8R_) 2008 ►, Audi A5
Cabriolet (8F_) 2009 ►“, page 154

♦ ⇒ „9.1.10 Capacities for Audi 100 / Audi A6 (4A_) ► 1998“,

page 154
♦ ⇒ „9.1.11 Capacities for Audi A6 (4B_) 1998 ► and Audi allroad
(4B_) ► 2005“, page 155
♦ ⇒ „9.1.12 Capacities for Audi A6 (4F_) 2005 ►“, page 160
♦ ⇒ „9.1.13 Capacities for Audi A7 (4G_) 2011 ►“, page 160
♦ ⇒ „9.1.14 Capacities for Audi V8 (4C_) ► 1994“, page 161
♦ ⇒ „9.1.15 Capacities for Audi A8 (4D_) 1994 ►“, page 161
♦ ⇒ „9.1.16 Capacities for Audi A8 (4E_) 2003 ►“, page 162
♦ ⇒ „9.1.17 Capacities for Audi A8 (4H_) 2010 ►“, page 163
♦ ⇒ „9.1.18 Capacities for Audi Q7 (4L_) 2006 ►“, page 163
♦ ⇒ „9.1.19 Capacities for Audi R8 (42_) 2008 ►“, page 164
9.1.1 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 and ⇒ Electronic parts
catalogue
Vehicle model Production period Capacity in grammes Differing characteristics of this refrigerant
circuit
Audi A1 08.10 onwards 500 + / - 15 • None
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“ type „6 SEU 14C“ or „San‐
den“ type „7 PXE 16“ air conditioner compressors were fitted
⇒ Electronic parts catalogue and ⇒ Heating, air conditioning;
Rep. gr. 87 .
♦ Depending on the engine, „Delphi“ type „6 CVC 140“ air con‐
ditioner compressors may also be fitted at a later date (intro‐
duction not yet finalised) ⇒ Electronic parts catalogue and ⇒
Heating, air conditioning; Rep. gr. 87 .
9.1.2 Capacities for Audi A2 (8Z_) 2001 ►

• Restrictor (coloured).
• Reservoir.
• „Denso“ air conditioner compressor with no magnetic clutch
and with air conditioner compressor regulating valve -N280- .
9. Capacities for refrigerant R134a, refrigerant oil and approved refrigerant oils 145
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“.
Note
♦ Replacement restrictors with different holes are available (yel‐

low-coloured 1.54 mm, red-coloured 1.42 mm).
♦ Depending on manufacturer, colour of red restrictor may tend
more towards orange.
♦ To avoid altering the cooling output of the air conditioner, re‐
strictors with the same hole diameter must always be used.
♦ A restrictor with a smaller hole (red-coloured) and a condenser
with a smaller internal volume are installed from model year
2002 onwards. The capacity has therefore been slightly modi‐
fied (condenser -70 g, smaller restrictor +50 g) ⇒ Heating, air
conditioning; Rep. gr. 87 and ⇒ Electronic parts catalogue .
9.1.3 Capacities for Audi A3 (8L_) 1997 ► and

Audi TT (8N_) 1999 ►
• Expansion valve
• Receiver
• „Sanden“ or „Zexel / Valeo“ air conditioner compressor ⇒
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“

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
♦ If no replacement condenser with a flat tube width = 20 mm is
available for an Audi A3 and a condenser with a flat tube width
= 16 mm is fitted, only 650 + / - 20 g of refrigerant are to be
added instead of 750 + 50 g. In addition the capacity given on
the label must be altered accordingly (heed notes on Audi TT
⇒ page 148 ).
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 a flat tube width of 20 mm
to 10.03 (and from ⇒ page 148
06.04 to 08.04
⇒ page 148 )
From 10.03 onwards 650 + / - 20 • Condenser with a flat tube width of 16 mm
(except 06.04 to ⇒ page 148
08.04 ⇒ page 148 )
Note

♦ 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 148 . 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
(with part no. „ 8N0 820 411 A“) and the refrigerant circuit was
filled with 750 + 50 g of refrigerant. These vehicles were also
provided with a label indicating the wrong capacity, namely
750 g (or 700 g in 06.04) instead of 650 g ⇒ page 148 . 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 account of excess pressure in
the refrigerant circuit. Complaints may also be received about
engine performance (e.g. humming and drumming; the engine
is subjected to greater load as the air conditioner compressor
constantly has to cope with excessively high pressure). Rem‐
edy: Discharge the refrigerant circuit, then re-charge with the
correct capacity and replace the label with a label indicating
the correct capacity or delete the old capacity indicated on the
label and enter the new capacity in waterproof ink for example.
♦ Pay attention to flat tube dimensions if condenser is renewed.
If a condenser with different flat tube dimensions is to be fitted,
also replace the label indicating the refrigerant R134a capacity
or delete the old capacity and enter the new capacity in wa‐
terproof ink for example ⇒ Electronic parts catalogue .
Reading flat tube dimensions of condenser

♦ Flat tubes of condenser -A-
♦ Width of flat tubes -B-
Label indicating refrigerant R134a capacity

Pay attention to flat tube dimensions if condenser is renewed. If

a condenser with different dimensions is to be fitted, also replace
the label -A- indicating the refrigerant R134a capacity or delete
the old capacity and enter the new capacity in waterproof ink for
example ⇒ Electronic parts catalogue .
9.1.4 Capacities for Audi A3 (8P_) 2004 ►
Note
Applies to the Audi A3, Audi A3 Sportback and Audi A3 Cabriolet.

• 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 and ⇒
Electronic parts catalogue
circuit
Audi A3 From 05.03 on‐ 525 + / - 25 • None
wards
Note

♦ At the start of production exclusive use was made of type „7
SEU 16“ air conditioner compressors from „Denso“. From
model year 2004 onwards, a different „Denso“ compressor
(type „7 SEU 17“) has gradually been replacing the old one.
♦ With effect from Model Year 2004, „Zexel / Valeo“ (type
„DSC17E“) and „Sanden“ (type „PXE16“) air condtioner com‐
pressors were gradually introduced depending on the engine
Rep. gr. 87 .
♦ With effect from Model Year 2008, „Denso“ (type „6 SEU 14“)
and „Delphi“ air condtioner compressors were gradually intro‐
duced depending on the engine ⇒ Electronic parts catalogue
and ⇒ Heating, air conditioning; Rep. gr. 87 .
9.1.5 Capacities for Audi TT (8J_) 2007 ►

• Expansion valve
• Receiver
• „Denso“ or „Sanden“ air conditioner compressor with air con‐
ditioner compressor regulating valve -N280- ⇒ Heating, air
conditioning; Rep. gr. 87 and ⇒ Electronic parts catalogue
circuit
Audi TT From 08.06 on‐ 525 + / - 25 • None
• With 4 or wards
6-cyl. en‐
gine
Audi TT 03.09 onwards 500 + / - 25 • Different type of condenser fitted ⇒

• With 5-cyl. Electronic parts catalogue and ⇒ Heat‐
engine ing, air conditioning; Rep. gr. 87 .
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). Different makes
of air conditioner compressor may also be fitted at a later date
depending on the engine ⇒ Electronic parts catalogue and ⇒
♦ 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)
Rep. gr. 87 .
9.1.6 Capacities for Audi 80 (8A_ / 8C_), Audi Coupé (8B_), Audi Cabriolet (8G_)
► 2002
• Restrictor (not coloured).
• Reservoir
• „Zexel / Valeo“ air conditioner compressor ⇒ Heating, air con‐
ditioning; Rep. gr. 87 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 hole (1.54 mm) is yellow-coloured. The
restrictor with the larger hole (1.83 mm) is not coloured.
9.1.7 Capacities for Audi A4 (8D_) 1995 ►

• Restrictor
• Reservoir
• „Denso“ or „Zexel / Valeo“ air conditioner compressor ⇒ Heat‐
ing, air conditioning; Rep. gr. 87 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“ condenser (distin‐
guishing feature
⇒ page 152 )
From 11.98 onwards 550 + 50 • Restrictor coloured (yellow)

• „AWG“ condenser (distin‐
guishing feature
⇒ page 152 )
Audi RS4 From 05.00 onwards 650 + 50 • Restrictor coloured (yellow)
Note
♦ Restrictors with a modified hole have been installed at the fac‐

tory since November 1997 (yellow-coloured). The capacity
was increased by 50 g for vehicles with a yellow-coloured re‐
strictor.
♦ The Audi A4 was fitted with different air conditioner compres‐
sors depending on the engine and production period. Exclu‐
sive use was made at the start of production of „Zexel / Valeo“
air conditioner compressors. As of Model Year 1996, „Denso“
air conditioner compressors were gradually introduced for ve‐
hicles with 6-cylinder engines.
♦ Replacement restrictors with different holes (not coloured, yel‐
low-coloured, red-coloured) are available. If a vehicle is fitted
with a different restrictor, add more or less refrigerant depend‐
ing on type (⇒ Table). After charging, amend capacity stated
on label or affix label indicating new capacity.
♦ From November 1998 onwards, Audi A4 models have also
been fitted with „AWG“ condensers (initially approx. 10000
vehicles with chassis numbers between 8DXA 065 253 and
8DXA 077 026). The specified capacity for vehicles with these
condensers differs from those with „Showa“ condensers. The
condensers can be identified on the basis of certain charac‐
teristic features ⇒ page 152 .
♦ 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 and ⇒ Electronic parts catalogue .
Distinguishing features
of „Showa“ and „AWG“ condensers
Different manifolds:
A - Manifold on „Showa“ condenser
B - Manifold on „AWG“ condenser

Different connections to the pressure switch.

A - Connection area on „Showa“ condenser
B - Connection area on „AWG“ condenser
9.1.8 Capacities for Audi A4 (8E_) 2001 ►, Audi A4 Cabriolet (8H_) 2003 ►
• 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 RS4 From 07.05 onwards 440 + / - 20 • Red-coloured restrictor.
Note

♦ To avoid altering the cooling output of the air conditioner, only
red or yellow-coloured restrictors are to be fitted. Yellow-col‐
oured restrictors were fitted in model year 2001. Red-coloured
restrictors were introduced in model year 2002. The change
to the restrictor (on vehicles produced in model year 2001, a
red-coloured restrictor may also be fitted instead of a yellow-
coloured one) does not alter the capacity for these vehicles.
♦ At the start of production exclusive use was made of type „6
SEU 12“ and „7 SEU 16“ air conditioner compressors from
„Denso“. From model year 2004 onwards, different „Denso“
compressors (types „6 SEU 14“ and „7 SEU 17“) have gradu‐
ally replaced the old ones. ⇒ Air conditioning; Rep. gr. 87
(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 .
9.1.9 Capacities for Audi A4 (8K_) 2008 ►, Audi A5 Coupé and Sportback (8T_)
2008 ►, Audi Q5 (8R_) 2008 ►, Audi A5 Cabriolet (8F_) 2009 ►
• Expansion valve
• Receiver
• Refrigerant pipe with internal heat exchanger
pressor regulating valve -N280- ⇒ Air conditioning; Rep. gr.
catalogue
circuit
wards
Coupé and wards
Sportback
Audi Q5 From 09.08 on‐ 600 + / - 20 • None
wards
Audi A5 Cab‐ From 03.09 on‐ 600 + / - 20 • None
riolet wards
Audi RS 5 03.10 onwards 570 + / - 20 • None
Note
♦ The air conditioner compressors fitted at the start of production

are manufactured by „Denso“ (type „6 SEU 14“) for vehicles
with 4 and 6-cyl. engine and type „7 SEU 17“ for vehicles with
8-cyl. engine). Different makes of air conditioner compressor
may also be fitted at a later date ⇒ Electronic parts catalogue
and ⇒ Air conditioning; Rep. gr. 87 (vehicle-specific workshop
manual).
♦ The Audi RS 5 is fitted with a condenser with a smaller internal
volume. The capacity for this vehicle is therefore lower than
for the other vehicles of this series ⇒ Electronic parts cata‐
logue .
9.1.10 Capacities for Audi 100 / Audi A6 (4A_) ► 1998

• Restrictor not coloured
• Reservoir
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

Note
♦ If a vehicle is fitted with a yellow-coloured restrictor as re‐

placement for a non-coloured restrictor, add 50 g more refrig‐
erant than specified in the table. In addition, the capacity
specified on the label in the vehicle is to be checked and
amended if necessary or the existing label is to be replaced
with one indicating the correct capacity (affix over old label).
♦ Restrictors with modified hole (coloured) have been installed
at the factory since November 1997. In order to distinguish
between the two restrictor versions, the one with the smaller
hole (1.54 mm) is yellow-coloured. The restrictor with the larg‐
er hole (1.83 mm) is not coloured.
♦ The Audi 100 / Audi A6 features different air conditioner com‐
pressors depending on the engine and production period.
Exclusive use was made at the start of production of „Zexel /
Valeo“ air conditioner compressors. As of Model Year 1996,
„Denso“ air conditioner compressors were gradually intro‐
duced for vehicles with 6-cylinder engines.
♦ The air conditioner compressor designation „Zexel / Valeo“
was changed as of 2006 to „Valeo“.
♦ From September 1994, production was gradually switched
from condenser 4A0 260 403 AB to condenser 4A0 260 403
AC.
♦ The refrigerant capacity of 750+50 g applies to all Audi 100
models (regardless of condenser).
♦ Only condensers with part number 4A0 260 403 AC are now
available as replacement parts (if necessary use label, 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) ⇒
catalogue .
9.1.11 Capacities for Audi A6 (4B_) 1998 ► and Audi allroad (4B_) ► 2005
• Restrictor
• Reservoir
• „Denso“ or „Zexel Valeo“ air conditioner compressor ⇒ Air
and ⇒ Electronic parts catalogue
circuit
Audi A6 From 04.97 800 + 50 • Restrictor not coloured
to 11.97
• Air conditioner unit version „1“ ⇒ Air
conditioning; Rep. gr. 87 (vehicle-
• Condenser with flat tube dimensions
20 mm x 3 mm ⇒ page 159 .
circuit
From 11.97 850 + 50 • Restrictor coloured (yellow)
to 08.98
• Air conditioner unit version „1“ ⇒ Air
• Condenser with flat tube dimensions
20 mm x 3 mm ⇒ page 159 .
Note

was increased by 50 g for vehicles in which a yellow-coloured
restrictor was installed.
♦ If a vehicle is fitted with a coloured restrictor as replacement
for a non-coloured restrictor, add 50 g more refrigerant (see
table). In addition, the capacity specified on the label in the
vehicle is to be checked and amended if necessary or the ex‐
isting label is to be replaced with one indicating the correct
capacity (affix over old label).
♦ The Audi A6 is fitted with different air conditioner compressors
depending on the engine and production period.
♦ In August/September 1998, production was gradually switch‐
ed from air conditioning unit version „1“ to air conditioning unit
version „2“. A reduction in capacity was achieved as the evap‐
orator was also modified together with the air conditioning unit.
♦ The two air conditioner unit versions can be identified on the
basis of certain characteristics described in the vehicle-spe‐
cific workshop manual ⇒ Air conditioning; Rep. gr. 87 (vehi‐
cle-specific workshop manual) and ⇒ Electronic parts
catalogue .
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“ ⇒ Air
• With 6-cyl. specific workshop manual).
petrol en‐
gine • Condenser with part no. 4B0 260
401 (403) and index „D“, „E“ or
„F“ (flat tube dimensions 20 mm x 3
mm ⇒ page 159 ) ⇒ Electronic parts
catalogue .

Vehicle model Production period Capacity in grammes Differing characteristics of this refriger‐
ant circuit
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“ ⇒ Air
gine (see notes) conditioning; Rep. gr. 87 (vehicle-
• Condenser with part no. 4B0 260
401 (403) and index „D“, „E“ or
„F“ (flat tube dimensions 20 mm x 3
mm ⇒ page 159 ) ⇒ Electronic parts
catalogue .
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) Air conditioning; Rep. gr. 87 (vehicle-
gine specific workshop manual).
• Condenser with part no. 4B0 260 401
(403) and index „G“ or „R“ (flat tube
dimensions 16 mm x 1.7 mm
⇒ page 159 ) 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‐ Air conditioning; Rep. gr. 87 (vehicle-
cept 2.0 l specific workshop manual).
• With 6-cyl. • Condenser with part no. 4B0 260 401

petrol en‐ (403) and index „H“, „J“, „K“, „S“, „T“
gine ex‐ or „N“ (flat tube dimensions 18 mm x
cept 3.0 l 1.7 mm ⇒ page 159 ) and ⇒ Elec‐
engine tronic parts catalogue .
• With 6-cyl.
diesel en‐
gine (refer
to notes)
Audi A6 From 05.01 onwards 550 + 50 • Restrictor coloured (yellow)

• With 4-cyl.
engine 2.0 • Air conditioner unit version „3“ ⇒ Air
l conditioning; Rep. gr. 87 (vehicle-
• With 6-cyl.
engine 3.0 • Condenser with part no. 8E0 260 401
l (403) and index A (flat tube dimen‐
sions 18 mm x 1.7 mm ⇒ page 159 )
• 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 159 .
♦ On condenser replacement, 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 involved. 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 ex‐
isting label. The part number can be found on a sticker attach‐
ed to the bottom of the condenser.
♦ As of 04.99, production was gradually switched from condens‐
ers with flat tube dimensions 20 mm x 3 mm to condensers
with flat tube dimensions 18 mm x 1.7 mm or 16 mm x 1.7 mm.
The change in production took place gradually during the
course of 1999 depending on the engine and existing supplies
of the different versions. Refer to the Electronic parts cata‐
logue for precise assignment of the different condensers ⇒
Electronic parts catalogue .
♦ Vehicles with 6-cyl. diesel engine produced from 04.99 on‐
wards may be equipped with a condenser with index „D“, „G“,
„R“ or „K“. Observe the different capacities ⇒ Air conditioning;
Rep. gr. 87 (vehicle-specific Workshop Manual) and ⇒ Elec‐
circuit
Audi A6 • Up to 03.99 550 + 50 • Restrictor coloured (yellow).
• With 8-cyl.
engine and • Air conditioner unit version „2 or 3“ ⇒
• From 02.00 on‐ Air conditioning; Rep. gr. 87 (vehicle-
wards specific workshop manual).
(403) B, D, E (flat tube dimensions 18
mm x 1.7 mm ⇒ page 159 ) ⇒ Elec‐
Audi A6 From 03.99 to 02.00 650 + 50 • Restrictor coloured (yellow)

• With 8-cyl.
engine • Air conditioner unit version „2“ ⇒ Air
(403) C (flat tube dimensions 18 mm
x 1.7 mm ⇒ page 159 ) ⇒ 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 conditioner unit versions can be identified on
the basis of certain characteristics described in the workshop
manual ⇒ Air conditioning; Rep. gr. 87 (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 ⇒ Air conditioning; Rep. gr. 87 (vehicle-
Flat tube dimensions of 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 on condenser replacement
(sometimes the only distinguishing feature) ⇒ Electronic parts
catalogue .
Condensers -A- with flat tube dimensions -B- = 20 mm and -C- =

3.0 mm must be filled with more refrigerant than condensers -D-
with flat tube dimensions -E- = 18 mm or 16 mm and -F- = 1.7 mm
Pay attention to flat tube dimensions if condenser is renewed. If

a condenser with different dimensions is to be fitted, also renew
label -A- indicating the refrigerant R134a capacity or remove the
old capacity and record the new capacity using a waterproof pen
9.1.12 Capacities for Audi A6 (4F_) 2005 ►
Note
Also applies to the Audi S6 and Audi RS 6.

• Restrictor (red-coloured).
• Reservoir
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 RS6 From 05.08 onwards 500 + / - 20 • Red-coloured restrictor
• Condenser with smaller internal
volume
Note

red-coloured restrictors are to be fitted.
♦ Different air conditioner compressors are fitted depending on
the model ⇒ Air conditioning; Rep. gr. 87 (vehicle-specific
♦ 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 .
9.1.13 Capacities for Audi A7 (4G_) 2011 ►


• Expansion valve
• Receiver
• Refrigerant line with internal heat exchanger
catalogue
circuit
Audi A7 10.10 onwards 570+ / - 20 • None
Note
The air conditioner compressors fitted at the start of production

are manufactured by „Denso“ (type „6 SEU 14“). Different makes
of air conditioner compressor or another type of compressor may
also be fitted at a later date ⇒ Electronic parts catalogue and ⇒
Air conditioning; Rep. gr. 87 (vehicle-specific workshop manual).
9.1.14 Capacities for Audi V8 (4C_) ► 1994

• Reservoir
el ant circuit
Audi V8 From 10.92 850 + 50 • None
to 10.93
Note
♦ Replacement restrictors with different holes are available. If

these vehicles are fitted with a yellow-coloured restrictor, add
50 g more refrigerant than specified in the table. After charg‐
ing, amend capacity stated on label or affix label indicating
new capacity.
♦ In order to distinguish between the different restrictor versions,
the ones with a smaller hole are coloured (yellow or red). The
red-coloured restrictor is not to be used for these vehicles.

• Restrictor
• Reservoir
• „Denso“ or „Zexel / Valeo“ air conditioner compressor ⇒ Air
el ant circuit
Audi A8 From 05.94 750 + 50 • Restrictor not coloured.
to 11.97
11.97 onwards 800 + 50 • Restrictor coloured (yellow)
Note

was increased by 50 g for vehicles with a yellow-coloured re‐
strictor.
♦ In order to distinguish between the different restrictor versions,
the one with the smaller hole is coloured yellow (1.54 mm) or
red (1.42 mm). The restrictor with the larger hole (1.83 mm) is
not coloured.
♦ If a vehicle is fitted with a yellow-coloured restrictor as re‐
placement for a non-coloured restrictor, add 50 g more refrig‐
erant (see table). In addition, the capacity specified on the
label in the vehicle is to be checked and amended if necessary
or the existing label is to be replaced with one indicating the
correct capacity (affix over old label). The red-coloured re‐
strictor is not to be used for these vehicles.
♦ Exclusive use was made at the start of production of „Zexel /
production was gradually switched to „Denso“ air conditioner
compressors ⇒ Air conditioning; Rep. gr. 87 (vehicle-specific
9.1.16 Capacities for Audi A8 (4E_) 2003 ►

• Reservoir
el ant circuit
Audi A8 From 10.02 onwards 620 + / - 20 • Red-coloured restrictor.

Note

♦ Depending on the manufacturer, the colour of the red restrictor
may tend more towards orange.
♦ Only red-coloured restrictors are to be fitted, so as not to alter
the cooling capacity of the air conditioner.
the model ⇒ Air conditioning; Rep. gr. 87 (vehicle-specific
9.1.17 Capacities for Audi A8 (4H_) 2010 ►

• Expansion valve
• With one or two evaporator(s) depending on equipment
• Dryer cartridge in receiver at condenser
catalogue
circuit
Audi A8 03.10 onwards
♦ Vehicle 780 + / - 20 • One evaporator
with one
evaporator
♦ Vehicle 930 + / - 20 • Two evaporators

with two
evapora‐
tors
9.1.18 Capacities for Audi Q7 (4L_) 2006 ►

• Expansion valve
catalogue
circuit
Audi Q7 From 02.06 on‐
wards
circuit
♦ Vehicle 700 + 50 • One evaporator
with one
evaporator
♦ Vehicle 1050 + 50 • Two evaporators

with two
evapora‐
tors
9.1.19 Capacities for Audi R8 (42_) 2008 ►

• Reservoir
• Two series-connected condensers
catalogue
el ant circuit
Audi R8 From 03.07 onwards 650 + / - 20 • Red-coloured restrictor.
Note

♦ Depending on the manufacturer, the colour of the red restrictor
may tend more towards orange.
red-coloured restrictors may be fitted.
9.2 Approved refrigerant oils and refrigerant

oil capacities
Note
♦ As PAG (polyalkylene glycol) oil is highly hygroscopic (attracts

water), opened containers are to be immediately re-sealed so
as to be air-tight.
♦ PAG oil from containers which have been open for a lengthy
period is no longer usable.
♦ Approved refrigerant oils ⇒ page 165

♦ Refrigerant oil capacities ⇒ page 166

9.2.1 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 .
♦ 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 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) ⇒ Electronic parts catalogue .
♦ Use is to be made for refrigerant circuits with „Zexel / Valeo“
or „Sanden“ compressor of refrigerant oil with part no. G 052
154 A2 ⇒ 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“ compressors, use
can be made of both the refrigerant oil (G 052 154 A2) and the
refrigerant oil (G 052 200 A2) contained in the retrofit kit (part
no. 4A0 298 107) ⇒ Electronic parts catalogue .
9.2.2 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 or ⇒ Air con‐
ditioning; Rep. gr. 87 (vehicle-specific workshop manual) and
⇒ Electronic parts catalogue
♦ 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 replaced, 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 the refrigerant oil out of the replacement com‐
pressor (or the defective air conditioner compressor), a small
quantity of oil generally remains in the air conditioner com‐
pressor (20 to 30 cm3 ). This refrigerant oil does not affect the
function of the air conditioner and can therefore be ignored
(always remains in compressor).
♦ On initial switch-on, the refrigerant oil is distributed throughout
♦ For refrigerant oil topping-up quantities on replacing defective
refrigerant circuit components, refer to ⇒ page 136 . Also ⇒
Heating, air conditioning; Rep. gr. 87 , ⇒ Air conditioning; Rep.
gr. 87 (vehicle-specific workshop manual) and ⇒ Electronic
parts catalogue .
♦ ⇒ „9.2.3 Capacities for Audi A1 (8X_) 2011 ►“, page 167

♦ ⇒ „9.2.4 Capacities for Audi A2 (8Z_) 2001 ►“, page 168
♦ ⇒ „9.2.5 Capacities for Audi A3 (8L_) 1997 ► and Audi TT (8N_)
1999 ►“, page 169
♦ ⇒ „9.2.6 Capacities for Audi A3 (8P_) 2004 ►“, page 169
♦ ⇒ „9.2.7 Capacities for Audi TT (8J_) 2007 ►“, page 171
♦ ⇒ „9.2.8 Capacities for Audi 80 (8A_ / 8C_), Audi Coupé (8B_),
Audi Cabriolet (8G_) ► 2002“, page 172
♦ ⇒ „9.2.10 Capacities for Audi A4 (8E_) 2001 ►, Audi A4 Cab‐
riolet (8H_) 2003 ►“, page 173
♦ ⇒ „9.2.11 Capacities for Audi A4 (8K_) 2008 ►, Audi A5 Coupé
and Sportback (8T_) 2008 ►, Audi Q5 (8R_) 2008 ►, Audi A5
Cabriolet (8F_) 2009 ►“, page 175
♦ ⇒ „9.2.12 Capacities for Audi 100 / Audi A6 (4A_) ► 1998“,
page 176
♦ ⇒ „9.2.13 Capacities for Audi A6 (4B_) 1998 ► and Audi allroad
2005 ►“, page 177
♦ ⇒ „9.2.14 Capacities for Audi A6 (4F_) 2005 ►“, page 179
♦ ⇒ „9.2.15 Capacities for Audi A7 (4G_) 2011 ►“, page 180

♦ ⇒ „9.2.16 Capacities for Audi V8 (4C_) ► 1994“, page 181

♦ ⇒ „9.2.18 Capacities for Audi A8 (4E_) 2003 ►“, page 182
♦ ⇒ „9.2.19 Capacities for Audi A8 (4H_) 2010 ►“, page 183
♦ ⇒ „9.2.20 Capacities for Audi Q7 (4L_) 2006 ►“, page 185
♦ ⇒ „9.2.21 Capacities for Audi R8 (42_) 2008 ►“, page 187
9.2.3 Capacities for Audi A1 (8X_) 2011 ►

• Expansion valve
• Receiver
• Air conditioner compressor from various manufacturers with
air conditioner compressor regulating valve -N280- (no mag‐
netic clutch) ⇒ Heating, air conditioning; Rep. gr. 87 and ⇒
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 08.10 on‐ 110 + / - 10 110 + / - 10 • „Sanden“ (or „Delphi“)
wards air conditioner com‐
pressor
90 + / - 10 90 + / - 10 „Denso“ air conditioner

compressor
Note
♦ The replacement compressor contains the full quantity of oil

intended for the refrigerant circuit. On replacement, the quan‐
tity of oil in the air conditioner compressor is therefore to be
adjusted ⇒ page 136 .
the production period and engine.
♦ At the start of production, „Denso“ type „6 SEU 14C“ or „San‐
den“ type „7 PXE 16“ air conditioner compressors were fitted
Rep. gr. 87 .
♦ Depending on the engine, „Delphi“ type „6 CVC 140“ air con‐
ditioner compressors may also be fitted at a later date (intro‐
duction not yet finalised) ⇒ Electronic parts catalogue and ⇒
♦ These air conditioner compressors are available as replace‐
ment parts with different oil capacities and attention must
therefore be paid to the oil quantity in the air conditioner com‐
pressor as well as the exact part number ⇒ Heating, air
♦ 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 reduced system cooling output. Too little oil may
lead to lubrication problems in the air conditioner compressor.
♦ The air conditioner compressor may have been fitted at the
factory with a rating plate indicating the part number and the
quantity of refrigerant oil in the air conditioner compressor.
9.2.4 Capacities for Audi A2 (8Z_) 2001 ►

• Restrictor
• Reservoir
• Air conditioner compressor with air conditioner compressor
regulating valve -N280- (no magnetic clutch)
• „Denso“ air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87 and ⇒ Electronic parts catalogue .
Vehicle model Production period Total quantity of oil in refrig‐ Quantity of refrigerant oil in replace‐
erant circuit in cm3 ment compressor in cm3
Audi A2 From 06.00 onwards 180 +/ -15 180+/-15

Note

♦ As the air conditioner compressor 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 .
♦ As replacement air conditioner compressors of this type are
supplied with different oil capacities, the exact part no. must
be heeded ⇒ Electronic parts catalogue .
9.2.5 Capacities for Audi A3 (8L_) 1997 ► and Audi TT (8N_) 1999 ►
• Expansion valve
• Receiver
• „Sanden“ or „Zexel / Valeo“ air conditioner compressor ⇒
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
Note

9.2.6 Capacities for Audi A3 (8P_) 2004 ►
Note
Applies to the Audi A3, Audi A3 Sportback and Audi A3 Cabriolet.
• Expansion valve
• Receiver
• Air conditioner compressor from various manufacturers with
air conditioner compressor regulating valve -N280- (no mag‐
netic clutch) ⇒ Heating, air conditioning; Rep. gr. 87 and ⇒
sor in cm3
Audi A3 From 05.03 180 + / - 10 180 + / - 10 • „Denso“ air conditioner
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
From 08.07 110 + / - 10 110 + / - 10 • „Delphi“ air conditioner

onwards compressor

Note

the production period and engine.
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 .
♦ With effect from Model Year 2008, „Denso“ (type „6 SEU 14“)
and „Delphi“ air condtioner compressors were gradually intro‐
duced depending on the engine ⇒ Electronic parts catalogue
and ⇒ Heating, air conditioning; Rep. gr. 87 .
♦ This air conditioner compressor is available as a replacement
part with different oil capacities and attention must therefore
be paid to the oil quantity in the air conditioner compressor as
well as the exact part number ⇒ Heating, air conditioning; Rep.
gr. 87 and ⇒ Electronic parts catalogue .
9.2.7 Capacities for Audi TT (8J_) 2007 ►

• Expansion valve
• Receiver
• „Denso“ or „Sanden“ air conditioner compressor with air con‐
ditioner compressor regulating valve -N280- (no magnetic
clutch) ⇒ Heating, air conditioning; Rep. gr. 87 and ⇒ Elec‐
tronic parts catalogue
sor in cm3
Audi TT From 08.06 90 + / - 10 90 + / - 10 • „Denso“ air conditioner
14“ type
110 + / - 10 110 + / - 10 • „Sanden“ air condition‐

er compressor
Note
♦ The replacement air conditioner compressor contains the full

quantity of oil intended for the refrigerant circuit. On replace‐
ment, the quantity of oil in the air conditioner compressor is
therefore to be adjusted ⇒ page 136 .
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). Different makes
of air conditioner compressor may also be fitted at a later date
depending on the engine ⇒ Electronic parts catalogue and ⇒
♦ 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)
Rep. gr. 87 .
well as the exact part number ⇒ Heating, air conditioning; Rep.
gr. 87 and ⇒ Electronic parts catalogue .
9.2.8 Capacities for Audi 80 (8A_ / 8C_), Audi Coupé (8B_), Audi Cabriolet (8G_)
► 2002
• Reservoir

Audi 80 From 10.92 onwards 250 + 50 250 + 50
Audi Coupé
Audi Cabrio‐
let
Note

intended for the circuit. On replacement, the quantity of oil in
the air conditioner compressor is therefore to be adjusted
⇒ page 136 .

• Restrictor
• Reservoir
catalogue
Audi A4 From 11.94 onwards 250 + 50 250 + 50
Note

permitted unless authorised by AUDI AG. AUDI
depending on the engine and production period ⇒ Heating, air
9.2.10 Capacities for Audi A4 (8E_) 2001 ►, Audi A4 Cabriolet (8H_) 2003 ►
• Restrictor
• Reservoir
pressor regulating valve -N280- (no magnetic clutch) ⇒ Air

sor in cm3
Audi A4 From 11.00 180 + / - 10 180 + / - 10 • Air conditioner com‐
Audi RS4 to 01.04 pressor type „6 SEU
• All 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)
Note

depending on the engine and production period. As replace‐
ment air conditioner compressors of this type are supplied with
different oil capacities, the exact part no. must be heeded ⇒
ual) and ⇒ Electronic parts catalogue .
♦ At the start of production, the compressor types in the first line
of the table were supplied with a refrigerant oil quantity of 180
cm3 . 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 cm3 or 130
cm3 . 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 .

9.2.11 Capacities for Audi A4 (8K_) 2008 ►, Audi A5 Coupé and Sportback (8T_)
2008 ►, Audi Q5 (8R_) 2008 ►, Audi A5 Cabriolet (8F_) 2009 ►
• Expansion valve
• Receiver
• Refrigerant pipe with internal heat exchanger.
catalogue
sor in cm3
14“ and „7 SEU 17“
type

Coupé onwards compressor of „6 SEU
and 14“ and „7 SEU 17“
Sport‐ type
back
Audi Q5 From 09.08 150 + / - 10 150 + / - 10 • „Denso“ air conditioner
14“ and „7 SEU 17“
type
Audi A5 From 03.09 150 + /- 10 150 + / - 10 • „Denso“ air conditioner

Cabrio‐ onwards compressor of „6 SEU
let 14“ and „7 SEU 17“
type
Audi RS 03.10 on‐ 150 + /- 10 150 + / - 10 • „Denso“ air conditioner

5 wards compressor „7 SEU 17“
Note

are manufactured by „Denso“ (type „6 SEU 14“) for vehicles
with 4 and 6-cyl. engine and type „7 SEU 17“ for vehicles with
8-cyl. engine); this air conditioner compressor has no mag‐
netic clutch (it is constantly driven by the engine). Different
makes of air conditioner compressor may also be fitted at a
later date depending on the engine ⇒ Electronic parts cata‐
logue and ⇒ Air conditioning; Rep. gr. 87 (vehicle-specific
workshop manual).
well as to the exact part number ⇒ Air conditioning; Rep. gr.
catalogue .
9.2.12 Capacities for Audi 100 / Audi A6 (4A_) ► 1998

• Restrictor
• Reservoir
Audi 100 / From 10.92 250 + 50 250 + 50
Audi A6 to 03.97

Note

♦ The Audi 100 / Audi A6 features different air conditioner com‐
pressors depending on the engine and production period.
Exclusive use was made at the start of production of „Zexel /
„Denso“ air conditioner compressors were gradually intro‐
duced for vehicles with 6-cylinder engines ⇒ Air conditioning;
9.2.13 Capacities for Audi A6 (4B_) 1998 ► and Audi allroad 2005 ►
• Restrictor
• Reservoir
• „Denso“ or „Zexel / Valeo“ air conditioner compressor with air
conditioning system magnetic clutch -N25- ⇒ Air conditioning;
tronic 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
Audi A6/Audi all‐ From 04.97 250 + 50 250 + 50 • Refer to notes be‐
road to 05.01 low.
• 4-cyl. diesel en‐
gine
gine
(see notes for Audi
allroad)
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

♦ 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 is
being introduced gradually for the Audi allroad with 6-cyl. die‐
sel engine in Model Year 2003 ⇒ Air conditioning; Rep. gr.
catalogue .

• Restrictor
• Reservoir
catalogue
•
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)
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

♦ 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 is
being introduced gradually for the Audi allroad with 6-cyl. die‐
sel 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 number must be heeded
manual) and ⇒ Electronic parts catalogue .
9.2.14 Capacities for Audi A6 (4F_) 2005 ►
Note
Also applies to the Audi S6 and Audi RS 6.

• Restrictor
• Reservoir
catalogue
Audi A6/S6 From 04.04 onwards 130 + / - 10 130 + / - 10
Audi RS6 From 05.08 onwards 130 + / - 10 Depending on the version of the air
conditioner compressor (refer to note
below)
♦ 130 + / - 10
Note

adjusted.
♦ As there are different versions of this type of replacement air
conditioner compressor, the exact part no. must be heeded ⇒
ual) and ⇒ Electronic parts catalogue .
♦ On account of the different test bench procedure for this en‐
gine, the 10-cyl. TFSI engine (Audi RS 6) is fitted at the factory
with an air conditioner compressor with a smaller quantity of
refrigerant oil (70+ / - 10 cm 3
) than for the 10-cyl. FSI engine
(Audi S6) and the other engines (130+ / - 10 cm 3
) (at present,
the air conditioner compressors on the 10-cyl. FSI and the 10-
cyl. TFSI only differ in terms of the part number and the
quantity of refrigerant oil; refer also to the air conditioner com‐
pressor rating plate). To adjust the total quantity of oil in the
refrigerant circuit at the factory, the missing amount of oil in
the air conditioner compressor (60+ / - 10 cm 3
) with the 10-
cyl. TFSI engine (Audi RS 6) is added at a different point in the
refrigerant circuit. This is not necessary when performing serv‐
ice work, as replacement air conditioner compressors are only
supplied with the original quantity of oil (130+ / - 10 cm 3
)
(would only be required as part of service work if a new air
conditioner compressor with the smaller quantity of oil were to
be installed) ⇒ Electronic parts catalogue .
9.2.15 Capacities for Audi A7 (4G_) 2011 ►

• Expansion valve
• Receiver
catalogue
sor in cm3
Audi A7 10.10 on‐ 120 + / - 10 120 + / - 10 • „Denso“ air conditioner
wards compressor of „6 SEU
14“ type with oil sepa‐
rator

Note

are manufactured by „Denso“ (type „6 SEU 14“). Different
makes of air conditioner compressor or another type of com‐
pressor may also be fitted at a later date ⇒ Electronic parts
catalogue and ⇒ Air conditioning; Rep. gr. 87 (vehicle-specific
workshop manual).
well as to the exact part number ⇒ Air conditioning; Rep. gr.
catalogue .
9.2.16 Capacities for Audi V8 (4C_) ► 1994

• Reservoir
• Air conditioner compressor from „Zexel / Valeo“ ⇒ Heating, air
Audi V8 From 10.92 250 + 50 250 + 50
to 10.93
Note


• Restrictor
• Reservoir
Audi A8 From 05.94 onwards 250 + 50 250 + 50
Note

♦ Exclusive use was made at the start of production of „Zexel /
production was gradually switched to „Denso“ air conditioner
compressors ⇒ Air conditioning; Rep. gr. 87 (vehicle-specific
9.2.18 Capacities for Audi A8 (4E_) 2003 ►

• Restrictor
• Reservoir
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 From 10.02 200 + / - 10 200+ / - 10 Air conditioner compres‐
• 8-cyl. petrol en‐ onwards 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)
Note

♦ As replacement air conditioner compressors of this type are
supplied with different oil capacities, the exact part number
must be heeded ⇒ Air conditioning; Rep. gr. 87 (vehicle-spe‐
cific 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 cm3 . 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 cm3 . 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 .
9.2.19 Capacities for Audi A8 (4H_) 2010 ►

• Expansion valve

catalogue
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 03.10
on‐
wards
♦ 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

Note
♦ The replacement compressor contains a certain quantity of

refrigerant oil (at present 130+ / - 10 cm 3
). This quantity of
refrigerant oil currently corresponds to the quantity of oil speci‐
fied for this refrigerant circuit on vehicles with one and two
evaporators. At present, vehicles with two evaporators are fil‐
led 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 replaced after cleaning the refrigerant circuit, it
is therefore not necessary on vehicles with two evaporators to
pour additional refrigerant oil into the refrigerant circuit. If the
air conditioner compressor is replaced without having to clean
the refrigerant circuit, the quantity of refrigerant oil in the new
air conditioner compressor to be fitted should be adjusted in
line with the quantity of oil poured out of the old compressor
⇒ page 136 .
♦ As replacement air conditioner compressors are supplied with
different oil capacities, the exact part number must be heeded
♦ Too much oil in the circuit results in higher pressures and re‐
duced air conditioner cooling output. Too little oil may lead to
lubrication problems in the air conditioner compressor. The
specified refrigerant oil quantities are therefore to be heeded.
9.2.20 Capacities for Audi Q7 (4L_) 2006 ►

• Expansion valve
catalogue
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‐ 145+/ - 15 ♦ 150+/ - 10 • One evap‐
cle (air con‐ orator
with ditioner
one • Air condi‐
compres‐ tioner
evap‐ sor for a
orator compres‐
vehicle sor type „7
with an 8- SEU
cyl. en‐ 16“ (refer
gine) to notes
♦ 140+/ - 10 below)
♦ Vehi‐ (air con‐ • Two evap‐

245 + / - 15 ditioner
cle orators
with compres‐ (refer to
two sor for a notes be‐
evap‐ vehicle low)
ora‐ with a 6-
tors cyl. en‐
gine)

Note
♦ The replacement compressor contains a certain quantity of

refrigerant oil (at present 140 or 150+ / - 10 cm 3
, depending
on the air conditioner compressor). This quantity of refrigerant
oil corresponds to the quantity of oil specified for this refriger‐
ant circuit on vehicles with one evaporator. On account of the
greater refrigerant pipe length and the second evaporator, ve‐
hicles with two evaporators require more refrigerant oil in the
refrigerant circuit (currently an additional 100 cm3 ). If the air
conditioner compressor is replaced after cleaning the refrig‐
erant circuit, this quantity of refrigerant oil therefore has to be
added to the refrigerant circuit on vehicles with two evapora‐
tors (e.g. poured into open pipes or component connections).
If the air conditioner compressor is replaced without having to
clean the refrigerant circuit, the quantity of refrigerant oil in the
new air conditioner compressor to be fitted should be adjusted
in line with the quantity of oil poured out of the old compressor
⇒ page 136 .
9.2.21 Capacities for Audi R8 (42_) 2008 ►

• Restrictor
• Reservoir
• Two series-connected condensers
catalogue
Audi R8 From 03.07 150 + /- 10 150+ / - 10 Air conditioner compres‐
onwards sor type „7 SEU 17“
Note


10 Test equipment and tools

♦ List of testers, tools and materials ⇒ page 189 .
♦ Tools and materials available from regional sales centre or
importer ⇒ page 191 .
♦ Commercially available tools and materials ⇒ page 194 .
♦ Improvised tools ⇒ page 195 .
10.1 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 189 .
♦ Commercially available tools and materials ⇒ page 190 .
♦ Improvised tools ⇒ page 191 .
10.1.1 Tools and materials available from regional sales centre or importer
Designation Page
Air conditioner service station with flushing kit (for currently available air Refer to illustration and ⇒ V.A.G
conditioner service stations, refer to ⇒ V.A.G Workshop equipment cata‐ Workshop equipment catalogue
logue )
– With integrated program for flushing refrigerant circuit with refrigerant
R134a as well as the corresponding flushing kit
Flushing kit for refrigerant circuits (currently available flushing kits) ⇒ ⇒ V.A.G Workshop equipment
V.A.G Workshop equipment catalogue catalogue
– 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)
Adapter set for refrigerant circuits -VAS 6338/1- ⇒ V.A.G Workshop equipment
– For connecting air conditioner service station to refrigerant circuit and catalogue
for bridging certain removed components when flushing
Leak detector V.A.G 1796 Refer to illustration
Puller for magnetic clutch (Zexel / Valeo air conditioner compressor) Refer to illustration
V.A.G 1719
Adapter set for refrigerant circuit R134a V.A.G 1785/1-10 Refer to illustration
– 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 Refer to illustration
Adapter set with service connection V.A.G 1786 Refer to illustration
Combined fine filter unit for compressed-air system (oil, dirt and water Refer to illustration
separator as used for painting facilities) ⇒ Workshop equipment cata‐
logue
O-rings ⇒ Electronic parts catalogue Refer to illustration
Refrigerant oil ⇒ Electronic parts catalogue Refer to illustration
10. Test equipment and tools 189

Designation Page
Leak detection system VAS 6201 comprising: Refer to illustration
♦ 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 Refer to illustration and ⇒ V.A.G

Workshop equipment catalogue
Release tools for air conditioner pipes -T40149/- ⇒ V.A.G Workshop equipment
catalogue
Disassembly tool for refrigerant line quick-release couplings -T40232- ⇒ V.A.G Workshop Equipment
catalogue
10.1.2 Commercially available tools and materials

Designation 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
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
Protective gloves Not illustrated
Safety goggles Not illustrated
Refrigerant R134a with cylinder (capacity as required) Not illustrated

10.1.3 Improvised tools

Designation Page
Filler hose with connection to compressed-air system for workshop Not illustrated
10.2 Tools and materials available from re‐

gional sales centre or importer
Service station / air conditioner service station (this illustration
shows V.A.G 1885 for example; for currently available air condi‐
tioner service stations, refer to ⇒ V.A.G workshop equipment
catalogue )
♦ 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 replaced 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 not shown here can also be
used ⇒ V.A.G Workshop equipment catalogue .
♦ 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 ⇒ V.A.G workshop equip‐
ment catalogue .
Note
♦ This air conditioner service station incorporates the following

familiar items: Charging cylinder, pressure gauge set, vacuum
pump, shut-off valves and charging hoses.
♦ One quick-release coupling each (for service connections on
high and low-pressure side) is included in the scope of delivery
of this air conditioner service station.
♦ Depending on the version, a current vacuum display (LED)
may appear after pressing the „Evacuation“ button again.
Leak detector V.A.G 1796

Leak detection system VAS 6201
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 59 or blow out with compressed air and nitrogen
⇒ page 55 .
A - 5/8"-18 UNF thread for conical seal
B - Union nut (for connection with O-ring) with thread
♦ M 18x1.5 V.A.G 1785/1
♦ M 20x1.5 V.A.G 1785/2
♦ M 24x1.5 V.A.G 1785/3
♦ M 28x1.5 V.A.G 1785/4
Adapter
B - Threaded connection for O-ring
♦ M 18 x 1.5 V.A.G 1785/5
♦ M 20 x 1.5 V.A.G 1785/6
♦ M 24 x 1.5 V.A.G 1785/7
♦ M 28 x 1.5 V.A.G 1785/8

Valve adapter
B - Internal thread with valve opener
♦ M 10 x 1.25 V.A.G 1785/9 (for connections with valve on high-
pressure end)
♦ M 12 x 1.5 V.A.G 1785/10 (for connections on low-pressure
end)
Note
♦ A Schrader valve is screwed into connection -A-.

♦ A valve opener must be installed in the charging hose con‐
nection.
♦ Various adapters from this adapter set are also included in the
adapter set for refrigerant circuits -VAS 6338/1- .
Adapter set for service connection V.A.G 1786

A - Adapter with union nut -V.A.G 1786/1- (only for connections
with small valve core at low-pressure side)
B - Filler hose with union nut 5/8"-18 UNF(short version)
C - Adapter with service connection -V.A.G 1786/2-
Note
♦ For connections with a large valve insert (standard on „Zexel /

Valeo“ compressors, gradual change to small valve insert as
of 10.94), use is to be made of adapter V.A.G 1785/10 (remove
valve from adapter V.A.G 1785/10 or install valve opener in
charging hose -B-).
Socket -T10364-
Note
For removing and installing service connections and valve cores

with refrigerant circuit discharged.

10.3 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
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 pressure reducer for nitrogen (maximum

reducing 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 end with nominal size 16 mm
♦ Low-pressure end with nominal size 13 mm
♦ 2x release tool (Sharan)
Note
This quick-release coupling is included in the scope of delivery of

the air conditioner service station.
10.4 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)

Air Conditioner With Refrigerant R134a

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Service Department. Technical Information

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Copyright © 2010 Audi AG, Ingolstadt A0053300220

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

87 – Air conditioning system

This requires careful study of the manual, coupled with suitable

This document is a compact reference work which should be kept

1.2 Other reference material

1. General information on air conditioning systems 1

♦ List of special tools and workshop equipment required for

1.3 Principles of air conditioning systems

1.3.1 Physical principles

When water is heated in a vessel (heat absorption), water vapour

1.3.2 Pressure and boiling point

2 Rep. gr.87 - Air conditioning system

Pressure may be given in various units: 1 MPa (megapascal) cor‐

Vapour pressure curve for refrigerant R134a

1.3.3 Vapour pressure table for refrigerant

1. General information on air conditioning systems 3

♦ At absolute pressure, „0 bar“ corresponds to an absolute vac‐

Temperature in °C Pressure in bar (gauge pres‐

1.4 Refrigerant R134a

4 Rep. gr.87 - Air conditioning system

♦ Critical point ⇒ page 5

1.4.1 Physical properties of refrigerant R134a

1.4.2 Critical point

Different types of refrigerant must never be mixed. The refrigerant

1.4.3 Environmental aspects of refrigerant

1.5 Properties of refrigerant R134a

1. General information on air conditioning systems 5

♦ Charge factor ⇒ page 7

1.5.1 Trade names and designations

♦ Different trade names may be used in other countries.

1.5.3 Vapour pressure

1.5.4 Physical properties of R134a

1.5.5 Reaction with metals

1.5.6 Critical temperature/critical pressure

6 Rep. gr.87 - Air conditioning system

1.5.7 Water content

1.5.9 Charge factor

1.5.10 Tracing leaks

Use must be made for the various refrigerants of leak detectors

1.6 Refrigerant oil

1. General information on air conditioning systems 7

R134a. In addition, the materials of the R134a air conditioning

♦ Do not store refrigerant oils in open containers as they are

♦ Properties of refrigerant oil ⇒ page 8

1.6.1 Properties of refrigerant oil

♦ On account of its chemical properties, the refrigerant oil is not

1.7 How air conditioning works

8 Rep. gr.87 - Air conditioning system

ditioner compressor increases the heat content and temperature

1.7.1 Comfort of vehicle occupants

1.7.2 Environmental aspects

1. General information on air conditioning systems 9

For environmental reasons, refrigerants must not be released into

1.8 General work safety

1.9 Product properties