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Audi 1999 TT Repair Manual Download Page 107

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not 
 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability 
     with respect to the correctness of information in this document. Copyright by AUDI AG.

5

Removal and Installation

4 and 6 Cylinder

⇒ “5.1 A/C Compressor, Removing From Bracket“, page 103

5 Cylinder

⇒ “5.2 A/C Compressor, Removing From Bracket“, page 106
⇒ “5.3 A/C Unit“, page 108
⇒ “5.4 Air Intake Grille“, page 114
⇒ “5.5 Air Intake Housing with Recirculating and Air Flow/Fresh

Air Door“, page 115
⇒ “5.6 Belt Pulleys“, page 117
⇒ “5.7 Climatronic Control Module J255 “, page 124
⇒ “5.8 Door Motors“, page 126
⇒ “5.9 Dust and Pollen Filter“, page 138
⇒ “5.10 Fresh Air Blower Control Module J126 “, page 140
⇒ “5.11 Fresh Air Blower Control Module J126 and Fresh Air

Blower V2 “, page 141
⇒ “5.12 Fresh Air Intake Cover“, page 142
⇒ “5.13 Front Upper Body Outlet Temperature Sensors G385 /

G386 “, page 143
⇒ “5.14 Heater Core“, page 144
⇒ “5.15 High Pressure Sensor G65 “, page 151
⇒ “5.16 Instrument Panel Vents“, page 152
⇒ “5.17 Interior Temperature Sensor Fan V42 “, page 153
⇒ “5.18 Refrigerant Circuit Components“, page 154
⇒ “5.19 Sunlight Photo Sensor G107 “, page 183
⇒ “5.20 Temperature Sensors“, page 184

5.1

A/C Compressor, Removing From

Bracket

Special tools and workshop equipment required
♦ Torque Wrench -V.A.G 1331/- (or 5-50 Nm equivalent)
♦ Locking Pin -T10060 A-

Audi TT 2007 ➤

Heating, Ventilation and Air Conditioning - Edition 01.2011

5. Removal and Installation    

103

Summary of Contents for 1999 TT

Page 1: ... AUDI AG AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG Repair Manual Audi TT 2007 Heating Ventilation and Air Conditioning Engine ID CEP B CDM A CET A CCT A BPY BUB CBR A Edition 01 2011 Service Service Department Technical Information ...

Page 2: ...psList of Workshop Manual Repair Groups Repair Group 80 Heating Ventilation 87 Air Conditioning 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 cours...

Page 3: ...stem Control and Regulation Components Outside Passenger Compartment 25 1 3 A C System Control and Regulation Components Inside Passenger Compartment 27 1 4 A C System Operating After Filling Refrigerant Circuit 28 1 5 A C and Refrigerant Safety Precautions 29 1 6 A C Air Distribution Housing Defroster Outlet Door 30 1 7 Adapter Cable for Activating Control Motors 30 1 8 Checking Electrical Compon...

Page 4: ...96 4 8 High Pressure Sensor G65 Checking Pressure Signal 96 4 9 Passenger Compartment Forced Air Extraction Checking 98 4 10 Plenum Chamber Water Drain Checking and Cleaning 100 4 11 Rear Window Defogger Checking 101 4 12 Wiring and Component Testing with Test Box VAG 1598A 101 5 Removal and Installation 103 5 1 A C Compressor Removing From Bracket 103 5 2 A C Compressor Removing From Bracket 106 ...

Page 5: ...rforming Guided Fault Finding on Heating System page 2 Checking the electrical components on the heating system refer to 1 4 Heating System Electrical Components page 2 Checking the electrical components actuated by the heating system refer to 3 3 Electrical Components Controlled by Heating System Checking page 16 1 2 Contact Corrosion Contact corrosion can occur if inappropriate fasteners bolts n...

Page 6: ...ce Control Module function starting with Ve hicle diagnosis testing and information system VAS5051B in the Guided Fault Finding function 1 4 Heating System Electrical Components The electrical components for the heating system are identical to the electrical components for the A C system The electrical test for the various heater components is done in the same way as the test for these components ...

Page 7: ...m VAS5051B in the Guided Fault Finding function Perform the following work after completion of repair opera tions Check Climatronic control module J255 DTC memory and erase any possible displayed malfunctions using Vehicle di agnosis testing and information system VAS5051B in the Guided Fault Finding function Check coding of Climatronic control module using Vehicle di agnosis testing and informati...

Page 8: ...rim must be unobstructed Checking refer to 4 9 Passenger Com partment Forced Air Ex traction Checking page 98 2 Intake Grille For Fresh Air Intake Check for proper seat ing prevents foreign ob jects e g leaves enter ing intake housing of heater unit Check the bonded seal for damage and proper seating This seal pre vents water from flowing through beneath the in take grille into heater in take hous...

Page 9: ...c control module J255 for controlling the heater However the measured value is used to calculate the permitted switch on time for the Heated Rear Window Z1 Measured value of Outside Air Temperature Sensor is evaluated by Instrument Cluster Control Module J285 and transmitted via Comfort CAN Bus system to the Climatronic control module J255 Check using Vehicle diagnosis testing and information syst...

Page 10: ...el Vents page 152 and Body Interior Rep Gr 70 Removal and Installation Instrument Panel 5 Instrument Cluster Control Module J285 With the outside air temperature display G106 The Instrument Cluster Control Module J285 evaluates the measured value of the Outside Air Tem perature Sensor G17 and then transmits it via the Comfort databus system to the Climatronic control module J255 Check using Vehicl...

Page 11: ...alled These control modules possess an added function for the ex panded change indicator that is part of the efficiency indicator for the on board computer Therefore no heating system control head with part number 8J0 819 043 up through index G may be installed in a vehicle containing an expanded change indicator in the on board computer Refer to Electronic Parts Catalog ETKA Vehicle diagnosis tes...

Page 12: ...ng and installing refer to 5 3 A C Unit page 108 Note 3 Right Front Seat Temperature Sensor G345 and Right Front Heated Seat Z46 Seat heater is not installed in all vehicles optional equipment When the seat heater is activated it is displayed in the Climatronic control module J255 measured values block Refer to Vehicle diagnosis testing and information system VAS5051B in the Guided Fault Finding f...

Page 13: ...nel Vent Right Removing and installing instrument panel vents refer to 5 16 Instrument Panel Vents page 152 and Body Interior Rep Gr 70 Removal and Installation 2 4 Heater Components Observe notes for control and regulation of components in heater Refer to 1 5 Heater Activation and Control Components page 3 Note The air duct in the heater and in the vehicle is the same as on vehicles with A C syst...

Page 14: ...oving and instal ling refer to 5 8 2 Central Air Door Motor V70 V145 page 130 4 Auxiliary Air Heater Heating Element Z35 Only intended for vehicles with Diesel engine 5 Heat Exchanger For Heater Unit Removing and installing refer to 5 14 Heater Core page 144 6 Left Temperature Door Motor V158 With Left Temperature Door Potentiometer Actuator G220 Lever color identification white Removing and insta...

Page 15: ...be replaced separately will be introduced as a running change Refer to 1 14 Fresh Air Blower Control Module J126 and Fresh Air Blower V2 page 36 and Electronic Parts Catalog ETKA The Fresh Air Blower Control Module J126 is installed in the Fresh Air Blower V2 Depending on the version both of these components can be either replaced separately or only together Checking refer to Vehicle diagnosis tes...

Page 16: ...ed according to specifications Re fer to Engine Mechanical Rep Gr 19 General Information All air ducts covers and seals OK and properly installed Air flow through dust and pollen filter not obstructed by dirt Engine is warm Climatronic control module J255 DTC memory was checked and erased basic setting was performed and Climatronic con trol module coding was checked using VAS5051B in Guided Fault ...

Page 17: ...ot permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG Start the engine Audi TT 2007 Heating Ventilation and Air Conditioning Edition 01 2011 3 Diagnosis and Testing 13 ...

Page 18: ...e temperature of the air coming out of the left and right in strument panel vents is a maximum of 15 C greater than the previously measured environmental temperature the heater temperature increase is less than 16 C The temperature difference between the air coming out of the left and right instrument panel vents is less than 8 C Place Climatronic control module J255 temperature knob A in warm pos...

Page 19: ...fer to Engine Mechanical Rep Gr 19 General Information The integration of the heater core in the coolant circuit refer to Engine Mechanical Rep Gr 19 General Information Activation and function of Left Temperature Door Motor V158 using VAS5051B in Guided Fault Finding The foam seal on the heater core Refer to 5 14 Heater Core page 144 Function of temperature doors in air distribution housing Re fe...

Page 20: ...d test at increased engine speed at least 10 minutes engine speed greater than 2500 RPM Select a low gear during the test to prevent excessive vehicle speed If customer complains of poor heating performance at specific engine speeds check incorporation of heater core of heater in the coolant circuit If both coolant hoses supply and return of engine are interchanged coolant is flowing in the wrong ...

Page 21: ...ample Heated Rear Window Z1 and heated seats that do not belong to the heater are activated by the Climatronic control module J255 Check the electrical components as described in Guided Fault Finding it is the same on both vehicle with and without A C Refer to 4 4 Components Actuated by A C System Electrical Test page 91 and Vehicle diagnosis testing and information system VAS5051B in the Guided F...

Page 22: ...sions for example with or without voltage supply to the auxiliary heater heating element Z35 Refer to Electronic Parts Catalog ETKA Mark the allocation be fore disconnecting the connectors connectors of same shape for differ ent motors risk of inter changing them Secure wiring harness to mounting points pro vided on housing using cable ties or on mounts so that it does not come into contact with m...

Page 23: ... Motor V71 and Recirculation Door Motor V113 Removing and installing refer to 2 10 Air Flow Door Motor V71 Function page 62 After installing check both control motors which must be held in position by this bracket if they are not installed free of play use some foam to rectify play if necessary attaching it to inside of mounting points of bracket Refer to 2 10 Air Flow Door Motor V71 Function page...

Page 24: ...nd Electronic Parts Catalog ETKA The Fresh Air Blower Control Module J126 is installed in the Fresh Air Blower V2 Depending on the version both of these components can be either replaced separately or only together 17 Insulation Mat 18 Screw Clips 19 Cable Ties 20 Wiring Harness Bracket 4 2 Heater Note Remove the heater the same way as removing the A C unit The items that affect components that ar...

Page 25: ...ated cor rectly Removing and installing refer to 5 14 Heater Core page 144 7 Screw Tightening specification 2 5 Nm 8 Coolant Pipes Disconnect and connect from heater core Refer to 5 14 Heater Core page 144 9 Foam Spacer Installed between grommet and heater 10 Grommet Install in the back of the plenum chamber before installing the heater refer to 5 3 A C Unit page 108 Installing refer to 5 3 A C Un...

Page 26: ...ETKA Heater version without an opening for installing a temperature sensor 15 Plug Present two times in different version Refer to 2 1 Air Routing and Distribution in Passenger Compartment page 44 4 3 Air Guide Channel Note Remove the heater the same way as removing the A C unit The items that affect components that are only present on the A C system are omitted Remove heater Refer to 5 3 A C Unit...

Page 27: ...the correctness of information in this document Copyright by AUDI AG 1 Lower Section Of Air Guide Channel 2 Noise Insulation In vehicles without A C system with heater on ly a foam core piece is installed for noise insu lation instead of evapo rator 3 Clip 4 Upper Section Of Air Guide Channel 5 Screw Audi TT 2007 Heating Ventilation and Air Conditioning Edition 01 2011 4 Disassembly and Assembly 2...

Page 28: ...ust and Pollen Filter with Activated Charcoal Insert page 33 1 13 Evaporator Cleaning with Ultrasound A C Cleaner page 34 1 14 Fresh Air Blower Control Module J126 and Fresh Air Blower V2 page 36 1 15 Painting Vehicles with A C page 36 1 16 Performing Guided Fault Finding page 36 1 17 Refrigerant Circuit Draining page 36 1 18 Refrigerant Circuit Repairs page 37 1 19 Refrigerant Circuit Servicing p...

Page 29: ...ble belt guide Remove the A C compressor from engine if equipped Refer to 5 1 A C Compressor Removing From Bracket page 103 or 5 2 A C Compressor Removing From Bracket page 106 1 2 A C System Control and Regulation Components Outside Passenger Com partment Note If there is a malfunction in the system first check the Clima tronic control module J255 DTC memory Refer to Vehicle diagnosis testing and...

Page 30: ... may be installed in refrigerant lines on certain versions not planned at this time introduction not yet finalized Refer to Electronic Parts Catalog ETKA As with connections on var ious components these connection points may only be loos ened and opened when the refrigerant circuit is empty Refer to 1 19 Refrigerant Circuit Servicing page 38 and Refrigerant R134a Servicing Rep Gr 00 Description an...

Page 31: ...d information system VAS5051B in the Guided Fault Finding function Servicing operations on refrigerant circuit are described in 1 19 Refrigerant Circuit Servicing page 38 Perform the following work after completion of repair opera tions Check Climatronic control module J255 DTC memory and erase any possible displayed malfunctions using Vehicle di agnosis testing and information system VAS5051B in ...

Page 32: ...ration so much that the A C compressor will be damaged A C Compressor Regulator Valve N280 is not activated when the refrigerant circuit is empty and the A C compressor idles with the engine If there is no refrigerant then the refrig erant oil which is needed to lubricate the A C compressor will be not be transported the A C compressor will be lubricated by an internal oil circuit If it is necessa...

Page 33: ...ditioner are filled with the following refrigerant 1 1 1 2 Tetrafluorethane CF3 CH2F or CH2F CF3 Currently this refrigerant is known under the following trade names R134a H FKW 134a SUVA 134a and KLEA 134a other trade names may be used in other countries Safety precautions Refer to 1 20 Refrigerant Safety Precautions page 41 Discharge refrigerant circuit Refer to 1 17 Refrigerant Circuit Draining ...

Page 34: ...using with a door in the air outlet to the defroster vents in the instrument panel with a side cut out B that has been or will be installed exception vehicles that will only be driven in tropical regions On vehicles which will be driven in tropical areas only to pre vent the windshield from fogging up on the outside in the area of the Defrost outlet a door in the air outlet to the defroster vent i...

Page 35: ...e diagnosis testing and infor mation system VAS5051B in the Guided Fault Finding function The temperature dependent resistance values for the various temperature sensors are in the table They can be accessed with the Guided Fault Finding function using Vehicle diag nosis testing and information system VAS5051B in the Gui ded Fault Finding function Wires and Components Testing with Test Box V A G 1...

Page 36: ...tting to the A C heater according to Vehicle diagnosis testing and information system VAS5051B in the Guided Fault Finding function The Climatronic control module buttons and rotary switches are lit with light diodes LEDs that cannot be replaced The function and indicator lights in the buttons and in the rotary switches cannot be replaced separately If the Instrument Panel Interior Temperature Sen...

Page 37: ...s the version installed on a 5 cylinder vehicle with a Denso condenser Refer to the Electronic Parts Catalog ETKA The dryer cartridge F and the O ring B are the same in all condenser versions Should a repair set is not be available either replace the condenser completely or use the parts from the repair set from another condenser in this example from the repair set from the condenser installed in ...

Page 38: ...e dust and pollen filter earlier than planned on vehicles that operate in areas with high levels of pollution the activated charcoal layer in the dust and pollen filter is sa turated faster than planned a saturated filter can no longer absorb pollutants and the pol lutants can flow through freely 1 13 Evaporator Cleaning with Ultrasound A C Cleaner Tools required Ultrasound A C Cleaner VAS 6189 Cl...

Page 39: ...ff Open instrument panel vents and set the lowest temperature possible on the Climatronic control module J255 Cold tem perature setting Close the windows and the sunroof Set Climatronic control module to lowest fresh air blow level and select Instrument panel vent for air flow direction Cleaning Shake the bottle of VAS 6189 1 and then fill the VAS 6189 Be sure to read the Operating Instructions th...

Page 40: ...ferent versions of the Climatronic control module J255 Pay attention to precise assignment on replacement Refer to Electronic Parts Catalog ETKA A C system OBD is performed in the Guided Fault Finding function with the Vehicle diagnosis testing and information system VAS5051B in the Guided Fault Finding function The Climatronic control module can currently be exchanged as usual component protectio...

Page 41: ... internal oil circuit as long as there is enough refrigerant oil in the A C compressor 1 18 Refrigerant Circuit Repairs WARNING Before working on electrical system wiring remove relevant fuse s Note Disconnect battery before starting electric welding work on vehi cle Refer to Electrical Equipment Rep Gr 27 Removal and Installation The A C refrigerant system may be drained and opened only if it is ...

Page 42: ...ng in poorly ventilated areas and in workshop pits even if it is not noticeable Note The escaping refrigerant air mixture should not be inhaled but should be sucked out via an existing exhaust ventilation system Do not attempt repair on filled air conditioning systems by solder ing brazing or welding This pertains also for welding and sol dering work on the vehicle in the event that parts of the c...

Page 43: ...nt circuit are described in this Repair Manual Refer to 1 2 A C System Control and Regulation Components Outside Passenger Compartment page 25 Note The connections for the senders switches described in this Work shop Manual are fitted with a valve which closes automatically when the switches are unscrewed These switches can thus be replaced in any Audi and Volkswagen workshop even though the refri...

Page 44: ...d Zexel Refer to Refrigerant R134a Servicing Rep Gr 00 Specifications Beginning the production year 2006 the name of the Zexel A C compressor was changed from Zexel to Valeo Coat the O ring seals lightly with refrigerant oil prior to instal lation Refer to 1 21 Refrigerant Circuit O rings page 41 The specified diameters for O rings and the tightening torque pertain also to the threaded connections...

Page 45: ...tems are therefore to be switched on and use made of both rubber gloves and protective goggles Reason Intensive exposure to refrigerant on unprotected parts of the body will result in frostbite WARNING Keep an eye bath on hand If liquid refrigerant has come in contact with your skin and eyes immediately flush with cool water for 15 minutes Then apply eye drops and consult a doctor immediately even...

Page 46: ...b are different depending on installation location Refer to the Electronic Parts Catalog ET KA In addition to the color coded O ring seals use is also made at the factory of black O ring seals for certain connections 1 22 Refrigerant R134a Refrigerant R134a and refrigerant oil capacities refer to Re frigerant R134a Servicing Rep Gr 00 Specifications Bleed evacuate and fill the refrigerant circuit ...

Page 47: ...uit Refer to Electronic Parts Catalog ETKA and Refrigerant R134a Servicing Rep Gr 00 Specifications Compressor as replacement part has different oil fill capaci ties therefore note the exact part number Refer to Electronic Parts Catalog ETKA and Refrigerant R134a Servicing Rep Gr 00 Specifications The reason for the different oil capacities in the compressor is the design of the compressor itself ...

Page 48: ...using page 68 2 14 Air Guide In Air Distribution Housing page 69 2 15 High Pressure Sensor G65 Signal page 72 2 1 Air Routing and Distribution in Passen ger Compartment Note Air intake apparatus air outlet and air guide in A C unit refer to 2 12 Air Intake and Outlet Openings page 67 2 13 Air Guide In Evaporator Housing page 68 and 2 14 Air Guide In Air Distribution Housing page 69 Component locat...

Page 49: ...oster Outlet Door page 30 and to the Electronic Parts Catalog ETKA Make sure the correct Climatronic control module is installed and then check the adaptation using Vehicle diagnosis testing and information system VAS5051B in the Guided Fault Finding func tion On vehicles without A C the change to the door has no influence on the heater control the door is controlled only by adjusting the Climatro...

Page 50: ...ed out of the plenum chamber Refer to 5 12 Fresh Air Intake Cover page 142 12 Removing Air From The Passenger Compartment In Recirculating Air Mode The air is taken from the passenger footwell under the glove compartment 13 Air Duct Instrument Panel Vent Intermediate Piece To the three instrument panel vents in the center and to the left and right instrument panel vents Removing and installing ref...

Page 51: ... has the nec essary tools and in which the work can be performed accordingly by qualified personnel Refer to Refrigerant R134a Servicing Rep Gr 00 General Infor mation Heating and A C unit removing and installing refer to 5 3 A C Unit page 108 Heating and A C unit disassembling and as sembling refer to 6 Disassembly and Assembly page 186 Clean air conditioning system evaporator with Ultrasound A C...

Page 52: ... of air intake shroud there may be an opening here for installing the temperature sensor the temperature sensor pictured is not installed on the Audi TT if there is an opening in the air intake shroud it is seal with a grommet if necessary 13 Fresh Air Blower Control Module J126 and Fresh Air Blower V2 Removing and installing refer to 1 14 Fresh Air Blower Control Module J126 and Fresh Air Blower ...

Page 53: ...ant lines disconnecting and reconnecting refer to 5 18 13 Refrigerant Lines Disconnecting and Connecting From Expansion Valve page 180 Removing and installing refer to 5 18 10 Expansion Valve page 174 Note 2 3 Refrigerant Circuit Components Over view Note Repair work on refrigerant circuit refer to 1 18 Refrigerant Circuit Repairs page 37 All work or components marked with 1 can be repaired re pla...

Page 54: ...by Denso type 6 SEU 14 were installed A C compressors from other manufacturers for example Sanden type PXE 16 or ZJX can be installed later Refer to Refrig erant R134a Servicing Rep Gr 00 Specifications and Electronic Parts Catalog ETKA These A C compressors are available as replacement parts with different oil fill capacities therefore note capacity on the A C compressor and the exact part number...

Page 55: ...Rep Gr 00 Diagnosis and Testing Depending on engine version it may be necessary to remove some components for example EVAP canister in order to be able to connect to service coupling WARNING Only remove service connections when the refrigerant circuit is emp ty The connection does not have a valve 11 Sealing Cap With a seal Always screw on 12 Expansion Valve 13 Evaporator 14 Low Pressure Side Serv...

Page 56: ... Belt Pulley removing and installing refer to 5 6 1 Denso A C Compressor Version 1 page 117 1 Circlip With Rubber Disc Remove carefully using a small screwdriver or needle nose pliers es pecially note belt pulley when doing this Removing and instal ling refer to 5 6 1 Denso A C Compressor Version 1 page 117 The rubber disc that is vulcanized on serves as noise insulation during low compressor outp...

Page 57: ...C compressor flange before sliding on pulley 2 5 Belt Pulley Denso A C Compressor Version 2 Note If overload protection of pulley triggers check the A C com pressor for ease of motion before replacing the pulley If the A C compressor creates friction replace it completely To remove belt pulley it depends on engine version if it is necessary to remove A C compressor from engine Refer to 5 1 A C Com...

Page 58: ... with tire mounting paste or a soap solution as a lubricant Removing and instal ling refer to 5 6 1 Denso A C Compressor Version 1 page 117 Tightening specification 30 Nm 3 Circlip Replace install on correct side flat side toward A C compressor Removing and installing refer to 5 6 1 Denso A C Compressor Version 1 page 117 4 Belt Pulley Belt pulley is made of plastic and is sensitive to impact ther...

Page 59: ...A C compressor re moving and installing refer to 5 18 2 A C Compres sor page 157 Depending on time peri od of production and on engine compressor construction type may vary Refer to 2 3 Refrigerant Circuit Components Overview page 49 and Electronic Parts Catalog ETKA Ribbed belt removing and installing Refer to Engine Mechanical Rep Gr 13 Removal and Instal lation Note Replace the belt pulley Refe...

Page 60: ...nel Refer to Refrigerant R134a Serv icing Rep Gr 00 General Information Removing and installing refer to 5 18 11 Fluid Reservoir page 175 Note Dryer cartridge on a condenser with an integrated fluid reservoir removing and installing refer to 1 11 Dryer Cartridge page 33 8 Condenser May be removed only after draining refrigerant circuit Bring vehicle to a workshop that has the necessary tools and w...

Page 61: ... Coolant Fan and Coolant Fan 2 directly via the Coolant Fan Control Control Module J293 continuously to the desired output depending on engine type Check using Vehicle diagnosis testing and information system VAS5051B in the Guided Fault Finding and Wiring diagrams Troubleshooting Component locations 2 High Pressure Sensor G65 Function removing and installing refer to 5 15 High Pressure Sensor G65...

Page 62: ...revents foreign objects such as leaves entering the A C intake housing Check the bonded seal for damage and proper seating This seal prevents water from flowing through beneath the intake grille into heating A C unit intake housing Removing and installing refer to 5 12 Fresh Air Intake Cover page 142 7 Condensation Drain Checking removing and installing refer to 4 5 Condensation Water Drain Hose C...

Page 63: ...5 using Vehicle diagnosis test ing and information sys tem VAS5051B in the Guided Fault Finding 3 Diagnostic Connection Perform On Board Diagnostic OBD on A C system using Vehicle diagnosis testing and information system VAS5051B in the Guided Fault Finding 4 Left Front Upper Body Outlet Temperature Sensor G385 Right Front Upper Body Outlet Temperature Sensor G386 Removing and installing refer to ...

Page 64: ...ndex D Refer to the Electronic Parts Catalog ETKA and Vehicle diagnosis testing and information system VAS5051B in the Guided Fault Finding Starting with model year 2011 A C system control heads part number 8J0 820 043 beginning with index BA shall be gradually installed These control modules possess an added function for the ex panded change indicator that is part of the efficiency indicator for ...

Page 65: ...3 Evaporator Cleaning with Ultra sound A C Cleaner page 34 Heating and A C unit removing and installing refer to 5 3 A C Unit page 108 3 Right Front Seat Temperature Sensor G345 and Right Front Heated Seat Z46 Seat heater is not installed in all vehicles optional equipment Activation of seat heater is displayed in Climatronic control module J255 checking use Vehicle diag nosis testing and informat...

Page 66: ...ction via the output diagnostic test mode Vehicle diagnosis testing and informa tion system VAS5051B in the Guided Fault Finding or check it without a tester as follows if not using a tester con nect both contacts 5 and 6 on the adjustment motor s connec tor to a 12 volt DC source The adjustment motor will move in one direction up until the stop and will reverse direction if the plus and minus con...

Page 67: ... recirculation or vice versa the airflow door motor V71 and recirculation door motor V113 are activated as follows When switching from fresh air to recirculation mode the re circulation door E is first opened then the fresh air intake channel is closed via the back pressure fresh air door A When switching from recirculation to fresh air mode the fresh air intake channel is first closed by the back...

Page 68: ...compressor construction type may vary Refer to Electronic Parts Catalog ETKA At the start of production the A C compressors manufactured by Denso type 6 SEU 14 were instal led A C compressors from other manufacturers for example Sanden type PXE 16 or ZJX can be installed later Refer to Refrigerant R134a Servicing Rep Gr 00 Description and Operation and Electronic Parts Catalog ETKA These A C compr...

Page 69: ...ing signal refer to 4 8 High Pressure Sensor G65 Checking Pressure Signal page 96 8 Condenser Refrigerant lines disconnecting and reconnecting refer to 5 18 12 Refrigerant Lines Disconnecting and Connecting from Condenser page 178 Condenser removing and installing refer to 5 18 3 Condenser page 159 or 5 18 4 Condenser page 161 9 Fluid Reservoir Fluid reservoir is secured directly onto condenser Co...

Page 70: ...ving and installing evaporator from heating A C unit refer to 5 18 9 Evaporator page 172 14 Low Pressure Side Service Connection Different versions with primary sealing valve or with Schrader valve depending on refrigerant line dis tinguishing characteristics Refer to Refrigerant R134a Servicing Rep Gr 00 Description and Operation Refrigerant Circuit For the A C service station to measure pressure...

Page 71: ...the door with the side cut out the Climatronic control module J255 is changed Refer to 1 6 A C Air Distribution Housing Defroster Outlet Door page 30 and to the Electronic Parts Catalog ETKA Make sure the correct Climatronic control module installed and then check the adaptation using Vehicle diagnosis testing and information system VAS5051B in the Guided Fault Finding On vehicles without A C the ...

Page 72: ...71 and whose recirculation door is operated by the Recirculation door Mo tor V113 are installed 4 Fresh Air Blower V2 With Fresh Air Blower Control Module J126 5 Dust and Pollen Filter Follow the replacement intervals Refer to Main tenance Intervals Rep Gr 03 There are different versions of the dust and pollen filter with and without an activated charcoal insert Refer to the Electronic Parts Catal...

Page 73: ...pending on the measured temperatures the calculated sunlight intensity and setting on Climatronic control module the calculated specified outflow temperature and therefore the specified position of the temperature doors may be differ ent for the left and right side On the Audi TT with A C heating only only one temperature door motor is installed Both temperature doors for the left and right sides ...

Page 74: ...or Driver Side Shown in closed posi tion Central doors left right and center and both footwell doors are operated with each other via curved washers installed on control motor or on shaft 7 Air Guide Channel In The Driver Side Footwell 8 Air Distribution Housing Sectioned Above Line A A 9 Auxiliary Air Heater Heating Element Z35 Only intended for vehicles with Diesel engine 10 Heat Exchanger For H...

Page 75: ...ater controls 15 Air Distribution Housing Sectioned Above Line B B 16 Central Door Center Shown in open position Central doors left right and center and both footwell doors are operated with each other via curved washers installed on control motor or on shaft 17 Door In Air Guide Channel To Vent In Rear Center Console This door is non functional in the Audi TT the air guide channel to the vent in ...

Page 76: ...liability with respect to the correctness of information in this document Copyright by AUDI AG 2 15 High Pressure Sensor G65 Signal A Pressure on the high pressure side in the refrigerant circuit in bar absolute pressure B square wave signal duty cycle C Characteristic curve Audi TT 2007 Heating Ventilation and Air Conditioning Edition 01 2011 72 Rep Gr 87 Air Conditioning ...

Page 77: ...he A C com pressor is switched on The request from the Climatronic control moduled is displayed in the measuring value block Refer to Vehicle diagnosis testing and information system VAS5051B under Guided Fault Finding The request to activate the coolant fan is currently only sent to the databus system by the Climatronic control module at a specified pressure in the refrigerant circuit If the pres...

Page 78: ...high pressure sensor Note The display shows a signal that is transferred when the pres sure in the refrigerant circuit is approximately 7 bar it corre sponds to an approximate duty cycle of 25 with compressor not engaged an ambient temperature of 30 C and properly filled refrigerant circuit The impulse width A depends on the pressure in the refrig erant circuit if pressure increases area A gets wi...

Page 79: ...ons Component Fastener Size Nm Air Intake Grille 3 5 Compressor Drive Plate Denso Version 1 35 Denso Version 2 30 Sanden Drive Plate 25 Compressor Mounting Bolts 25 Coolant Pipes to Heater Core 2 5 Expansion Valve to Evaporator Bracket 10 Fluid Reservoir On Condenser 10 High Pressure Sensor 8 Oil Drain Plug Denso 30 Sanden 10 Pressure Relief Valve Denso 10 Sanden 14 5 Refrigerant Lines to Compress...

Page 80: ...amber Water Drain Checking and Cleaning page 100 4 11 Rear Window Defogger Checking page 101 4 12 Wiring and Component Testing with Test Box VAG 1598A page 101 4 1 A C Compressor Regulator Valve N280 Checking Switch On Signal Note The test for an A C compressor manufactured by Denso of type 6 SEU 14 is described in the following Test is to be performed in the same way for vehicles with a different...

Page 81: ...n nector B on A C compressor regulator valve using an adapter cable from Connector test kit V A G 1594 C Note The activation of the A C compressor regulator valve and the current that flows through the A C compressor regulator valve and which the Climatronic control module J255 measure are displayed on the Climatronic control module measured values block Check using Vehicle diagnosis testing and i...

Page 82: ...ng Start the engine Set temperature preselect on Climatronic control module J255 to Cold setting maximum cooling performance On Climatronic control module switch activation of A C Com pressor Regulator Valve N280 on and off by pressing the AC button with indicator light when compressor is on Shown on screen of oscilloscope depending on setting of Clima tronic control module In operating mode OFF o...

Page 83: ...p and the temperature preset is set to stop Cold then the A C compressor regulator valve is activated so that the maximum permissible current of approximately 0 65 A flows through the A C compressor reg ulator valve maximum A C compressor output In control mode actuation time is governed by required cool ing output and vehicle electrical system voltage for example It is however always of sufficien...

Page 84: ... indicator light on the AUTO button lights up Turn the temperature rotary switch to cold The A C compressor is on the indicator lamp on the AC button comes on Fresh air blower rotary switch in maximum speed stop Functions with engine running The radiator fan Coolant fan V7 and Coolant fan 2 V177 run activation and speed depend on pressure in coolant cir cuit and engine temperature Note Depending o...

Page 85: ...Switch on Econ in the Climatronic control module J255 in dicator light in AC button does not light up Initiate a Guided Fault Finding on the A C system using VAS5051B under Guided Fault Finding Select read measured values block display group with the measured values for the A C compressor control and the pres sure inside the refrigerant circuit and read the measured val ues using VAS5051B under Gu...

Page 86: ...and in which the work can be performed accordingly by qualified personnel In form the workshop of the fault insufficient refrigerant in the circuit Refer to Refrigerant R134a Servicing Rep Gr 00 General Information Refrigerant circuit pressure OK Switch the A C compressor on by selecting Auto on the Cli matronic control module J255 indicator lights in AUTO button and AC button light up Turn the Cl...

Page 87: ...alue approximately 2 to 5 C A value greater than 75 0 55A is displayed after vehicle start depending on temperature engine speed and vehicle voltage measured As soon as the temperature measured by the evaporator vent temperature sensor G263 nears the tar get value the activation and thus the compressor output is reduced Under certain operating conditions moisture in the refrigerant circuit can lea...

Page 88: ...ermining Malfunction if Specified Values Are Not Obtained page 85 If the measured value from the evaporator vent temperature sensor is greater than the measured value from the left front upper body outlet temperature sensor G385 then make sure the evaporator vent temperature sensor is installed correctly and perform an electrical test on this sensor using VAS5051B under Guided Fault Finding The fu...

Page 89: ...no fault found on the left footwell vent temperature sensor G261 right footwell vent temperature sensor G262 and evaporator vent temperature sensor G263 as well as on the left temperature door motor V158 and right temperature door motor V159 then determine the malfunction with tem perature increase downstream of the evaporator Refer to 4 2 4 Temperature Increase Downstream from Evaporator Determin...

Page 90: ...tools and in which the work can be performed accordingly by qualified per sonnel Refer to Refrigerant R134a Serv icing Rep Gr 00 General Information Bring the problems determined to the at tention of the workshop Repeat cooling output test Continuation of test Pressure in refrigerant circuit increases Open hood Repeat cooling performance test Refer to 4 2 A C Unit Checking Cooling Output page 79 R...

Page 91: ...rcuit pressure using the duty cycle signal from the high pressure sensor G65 display in the measured values block At a duty cycle less than 10 corresponds to approximately 1 2 bar absolute pressure and greater than 78 corresponds to approximately 32 bar absolute pressure Climatronic con trol module does not switch on the compressor A C Com pressor Regulator Valve N280 is not activated The A C comp...

Page 92: ...hich the measure value deviates for correct installation and its electrical connections for contact resistance using VAS5051B in Guided Fault Finding and Wiring diagrams Troubleshooting Component locations Check activation and function of Left Temper ature Door Motor V158 and of Right Tem perature Door Motor V159 Refer to 4 2 4 Temperature Increase Downstream from Evaporator Determining Malfunctio...

Page 93: ...ured value from the evaporator vent temper ature sensor G263 with the Read measuring value block function using VAS5051B under Guided Fault Finding If the sensor measured is too high under the operating condi tions reported by the customer even though the A C system is operating without difficulty at greater than e g 10 C de pending on ambient temperature check the evaporator vent temperature sens...

Page 94: ...ch as leaves pine needles etc collecting Due to water that cannot drain out of the plenum chamber Note Check plenum chamber water drains Refer to 4 10 Plenum Chamber Water Drain Checking and Cleaning page 100 Smell from air conditioner Note Odors originating in the heating and A C unit can mainly be detected in fresh air mode and recirculated air mode If a smell occurs only in fresh air or recircu...

Page 95: ...y A C System Electrical Test Note Various vehicle electrical components for example Heated Rear Window Z1 and heated seats that do not belong to the heater are activated by the Climatronic control module J255 Perform an electrical test as described in Guided Fault Finding using Ve hicle diagnosis testing and information system VAS5051B in the Guided Fault Finding function Checking the heated rear ...

Page 96: ... Door Motor V113 page 135 and Ve hicle diagnosis testing and information system VAS5051B under Guided Fault Finding Also if there is a complaint about moisture in the passenger compartment that only occurs when the is A C compressor is switched on and under certain environmental conditions check the output temperature of air from the evaporator using Vehicle diagnosis testing and information syste...

Page 97: ...There must be enough distance so that the water can drain out of the hose C Installing Installation is carried out in the reverse order while observing the following Install the condensation water drain B so that it is not twisted or pinched When installing the carpet take special care that it does not compress the condensation water drain B 4 6 Heating Performance Of A C System Checking 4 6 1 Hea...

Page 98: ...trol module was checked Refer to Vehicle diagnosis testing and information system VAS5051B under Guided Fault Finding Vehicle not exposed to sunlight 4 6 3 Heating Performance Checking The heat output test requirements are met Refer to 4 6 2 Heat Output Test Requirements page 94 Close hood Close doors windows and rear lid Open all dash panel vents Perform OBD on the A C system Refer to Vehicle dia...

Page 99: ... footwell vents In that case only the measured value from the temperature sensor in stalled in the selected vent may be used if necessary adjust air output direction so it alternates between instrument panel vents and footwell vents Check and compare the displayed values from the left front upper body outlet temperature sensor from the left footwell vent temperature sensor and from the right footw...

Page 100: ...ting and information system VAS5051B under Guided Fault Finding The function test for the heated seat activation is described in A C system Guided Fault Finding using VAS5051B in the Guided Fault Finding function If the voltage measured on terminal 30 falls below the value stored in the vehicle electrical system control module J519 then the heat seating power will be reduced to approximately 50 or...

Page 101: ... out side temperatures ambient temperature lower than 5 C A C System control heads the Climatronic control module with part number 8J0 820 043 through to index AJ might there fore make an incorrect DTC memory entry DTC memory entry high pressure sensor and fall below the lower thresh old If the fault is displayed as a sporadic fault at an outside temperature greater than 5 C calculated by the A C ...

Page 102: ...t and right luggage compartment trim ventilation openings A to both vent frames B in luggage compartment left and right for throughput Note To ensure proper function of passenger compartment ventila tion vent openings A in luggage compartment trim on left and right must not be sealed Closed ventilation slits in luggage compartment trim A or plugged air ducts to vent frames B can cause windows to f...

Page 103: ... A must be installed on the correct side Forced air extraction vent frames checking from outside remov ing and installing Remove rear bumper cover Refer to Body Exterior Rep Gr 63 Removal and Installation Check left and right vent frames A for throughput and sealing lips B for function Note Stuck sealing lips B can cause windows to fog In order for sealing lips B to close properly vent frame A can...

Page 104: ...e Fresh Air Blower V2 onto the evaporator together with the air con veyed If both water grommets B in water drains A right and left in plenum chamber are blocked by leaves and pine needles it may cause the drains to freeze up in winter and water can no longer drain out After a short drive heat emitted from engine and exhaust system melts the ice in the drains again and water may drain off again be...

Page 105: ...activation is occurring despite a request Check using VAS5051B under Guided Fault Finding The function test for the heated rear window is described in Guided Fault Finding vehicle electrical system control module J519 Refer to VAS5051B under Guided Fault Finding Vehicle electrical system control module controls the heated rear window Z1 The heated rear window stays switched on at outside temper at...

Page 106: ...ct to the correctness of information in this document Copyright by AUDI AG Wiring diagram for vehicle system to be tested refer to Wir ing diagrams Troubleshooting Component locations Note Perform an electrical test as described in Guided Fault Finding using VAS5051B under Guided Fault Finding Audi TT 2007 Heating Ventilation and Air Conditioning Edition 01 2011 102 Rep Gr 87 Air Conditioning ...

Page 107: ...124 5 8 Door Motors page 126 5 9 Dust and Pollen Filter page 138 5 10 Fresh Air Blower Control Module J126 page 140 5 11 Fresh Air Blower Control Module J126 and Fresh Air Blower V2 page 141 5 12 Fresh Air Intake Cover page 142 5 13 Front Upper Body Outlet Temperature Sensors G385 G386 page 143 5 14 Heater Core page 144 5 15 High Pressure Sensor G65 page 151 5 16 Instrument Panel Vents page 152 5 ...

Page 108: ...irection of operation of ribbed belt with chalk or felt tipped pen Running a used belt in the oppo site direction could destroy it Different A C compressors may be installed depending on en gine and country variant Refer to Electronic Parts Catalog ETKA Removing Remove upper engine cover Refer to Engine Mechanical Rep Gr 13 Removal and Installation for example on a 2 0L TFSI vehicle Mark running d...

Page 109: ...hings arrows in bracket or A C compressor Note This illustration shows the version of the A C compressor with pulley that is installed on the Audi TT Tighten bolts arrows tightening torque 25 Nm Connect electrical connector 1 on A C Compressor Regula tor Valve N280 Mount the ribbed belt onto the pulley Refer to Engine Me chanical Rep Gr 13 Removal and Installation Note After fastening the A C comp...

Page 110: ...gine or a different A C compressor slight changes may result depending on engine additional assemblies may need to be removed or loosened Do not discharge the refrigerant circuit do not remove refrig erant hoses and lines from the A C compressor Do not unfasten refrigerant pipes and corresponding clamps After removing the A C compressor tie it to the vehicle with wire Do not let it hang by the ref...

Page 111: ...bracket and se cure it to the body with wire Refer to page 107 Remove the screws from the subassembly bracket 2 Internal Multi Point Bolt 25 Nm 3 Internal Multi Point Bolt 25 Nm 4 Hex Socket Head Bolt 25 Nm 5 A C Compressor Removing and instal ling refer to 5 18 2 A C Compres sor page 157 6 Hex Bolts 25 Nm 7 Dowel Sleeves Quantity 2 Be careful to use the correct version and make sure the subassemb...

Page 112: ...nt pump 10 Ribbed belt pulley coolant pump 5 3 A C Unit Special tools and workshop equipment required Hose Clamps Up To 40 mm 3094 and Hose Clamps Up To 25 mm diameter 3093 Compressed air gun commercially available Cooling System Tester V A G 1274 and corresponding adapter Note Remove the heater in the same way as the A C unit Naturally the items that affect components that are only present on the...

Page 113: ... to Engine Mechanical Rep Gr 19 General Information Remove components that hinder access to mounting points A on heat shield B and to coolant hoses to heater core in engine compartment Refer to 5 18 13 Refrigerant Lines Disconnecting and Connecting From Expansion Valve page 180 Loosen heat shield B from plenum chamber bulkhead lay it aside or remove it completely Mark arrangement of coolant hoses ...

Page 114: ... replacement evaporator can be used preventing dirt and moisture from entering the system Remove glove compartment driver s side storage compart ment front part of center console and instrument panel Refer to Body Interior Rep Gr 70 Removal and Installation Note To prevent the instrument panel shell from damage instrument panel should be placed on a clean work bench which is covered with clean car...

Page 115: ...ies at top of A C unit Disconnect all electrical connections between vehicle wiring harness and the electrical components of A C on heater at harness connectors Note The wiring harness air conditioner heater is removed together with the A C unit with the heater Carefully pull right side of A C heater unit slightly toward rear far enough that bolt B on the right bracket A can be loos ened Note Only...

Page 116: ...towards passenger side Installation Installation is carried out in the reverse order while noting the fol lowing Two technicians are needed to install the A C unit heater Note Before installing check all gaskets and seals on A C heater for damage and replace if necessary Check securing of coolant pipes to heater core Insert the molded seal A working outward from the passen ger compartment into rea...

Page 117: ...talling the instrument panel make sure that the de frost intermediate piece its properly on A C unit heater and the defrost vent does not pinch the intermediate piece Refer to 2 1 Air Routing and Distribution in Passenger Compart ment page 44 After installing instrument panel check output direction and distribution of air flow from defroster vent to windshield Connect coolant hoses properly to hea...

Page 118: ... testing and information system VAS5051B under Guided Fault Finding Operate the A C system after filling the refrigerant circuit Re fer to 1 4 A C System Operating After Filling Refrigerant Circuit page 28 Note Note the information regarding operating the A C system after filling Refer to Refrigerant R134a Servicing Rep Gr 00 De scription and Operation A C Service Station If necessary check A C he...

Page 119: ...e the complete instrument panel and instrument panel crossmember Refer to Body Interior Rep Gr 70 Removal and Installation Remove the A C unit heater Refer to 5 3 A C Unit page 108 Disconnect the connector A Mark wire connection to connector B to Air Flow Door Motor V71 and disconnect it danger of interchange since con nectors B and C are of identical construction Mark wire connection to connector...

Page 120: ...ake sure mounting points F and G are seated correctly Install the wiring harness so that it cannot come in contact with any moving parts for example the motor actuating arm Install the A C unit heater Refer to 5 3 A C Unit page 108 Install the complete instrument panel and instrument panel crossmember Refer to Body Interior Rep Gr 70 Removal and Installation Check Climatronic control module J255 D...

Page 121: ... off from belt pulley D after removing circlip A To optimize noise reduction a circlip A with a rubber disc vulcanized on it is installed Refer to 2 4 Belt Pulley Denso A C Compressor Version 1 page 52 and Electronic Parts Catalog This rubber disc can reduce a clapping castanet like noise which occurs espe cially at belt pulley in vehicles with Diesel engine in A C system operating mode Econ AC of...

Page 122: ...sor install flat side facing compressor Insert rubber element D in belt pulley B according to illus tration When installing drive plate coat rubber element D lightly e g with tire mounting paste or soap solution as sliding com pound Insert the drive plate C far enough into rubber elements D see upper illustration until it contacts A C compressor shaft B Install the drive plate C on the compressor ...

Page 123: ... plate C overload protection activates rotate the pulley E using the outer part of the drive plate C so that the compressor shaft B and the hexagon head on the drive plate D inner part of the drive plate C do not rotate Removal Remove the cap A Hold the A C compressor input shaft B for example with a standard Allen wrench 7 mm and turn the drive plate C to gether with the pulley E in the direction...

Page 124: ...or shaft thread before mounting the drive plate Note The thread of the new drive plate has already been greased with a specific amount of a grease by the manufacturer When installing drive plate coat rubber element D lightly for example with tire mounting paste or soap solution as sliding compound Insert rubber element D in belt pulley B according to illus tration Press the drive plate rubber elem...

Page 125: ... the Electronic Parts Catalog Perform preliminary work as for removing belt pulley refer to 1 1 A C Compressor Belt Pulley Replacement page 24 Replacing a version 1 belt pulley installed in 5 cylinder TFSI ve hicles 1 Hex Head Nut Note To loosen and tighten hex nut hold belt pulley firmly in place using a standard band wrench with webbing Clean threads of hex nut and threads of A C com pressor sha...

Page 126: ... insertion edge A faces away from A C compressor install flat side facing the A C compressor When installing circlip note that it cannot be bent open more than is necessary for installation 6 Belt Pulley With Double Belt Guide Clean A C compressor flange before sliding on pulley With rubber elements B and threaded plates C for decoupling belt pulley from A C compressor input shaft rubber elements ...

Page 127: ...tall the bolts with thread locking com pound for example D 000 600 A2 Refer to the Electronic Parts Catalog 3 Drive Plate The overload protection securing spring elements takes over when the torque is excessive for exam ple if the A C compressor runs with resistance and the belt pulley runs freely without driving the A C compressor Drive plate spring elements damp vibrations and noise 4 Circlip Re...

Page 128: ...witch off ignition Place 3438 B on Climatronic control module A according to illustration left and right Carefully pull Climatronic control module in direction of arrow out of center console Caution To prevent damage to the Climatronic control module and center console do not pull too hard The Climatronic control module is held by the clips and brackets in the center console If clips are stuck the...

Page 129: ...er while observing the following When replacing a Climatronic control module observe exact allocation Refer to Electronic Parts Catalog ETKA Different versions with or without seat heating switch with different temperature unit ºC or ºF on temperature setting rotary switch rotary switches with black or silver chrome plated surface Heater control head replacement part number 8J0 819 043 starting wi...

Page 130: ...or Motor can only be removed without difficulty in fresh air mode stop and installed only in this position If the motor stops in a different position and can no longer be moved electrically into the fresh air mode stop replace it Removing Remove the glove compartment Refer to Body Interior Rep Gr 68 Removal and Installation If necessary switch on the ignition on and select Defrost on the Climatron...

Page 131: ... motor was removed in a different position or activated in the removed state it cannot be instal led If the gear A on the airflow door motor is not in B fresh air operation then connect motor via accompanying connector to the vehicle wiring harness Then switch on ignition and se lect Defrost operating mode on the Climatronic control mod ule J255 A C heater control head positioning motor moves to f...

Page 132: ...irculating air mode is closed Insert airflow door motor B opposite direction of arrow in mounts C and on toothed gear D So that toothed gear on motor A can be slid on toothed gear of air flow door short tooth C of motor toothed gear must align with short tooth interval D of toothed gear on shaft of air flow door B Install Recirculation Door Motor V113 Refer to 5 8 5 Recirculation Door Motor V113 p...

Page 133: ...nforma tion system VAS5051B in the Guided Fault Finding function Perform a basic setting on the A C and then check the A C DTC memory one more time Refer to Vehicle diagnosis test ing and information system VAS5051B in the Guided Fault Finding function Activate Airflow door motor V71 and recirculation door motor via Climatronic control module J255 as follows until toothed gear reaches stop recircu...

Page 134: ...d information system VAS5051B in the Guided Fault Finding function Using the functions Output diagnostic test mode and Basic setting the activation of A C system electrical components can be tested if necessary e g allocation test using Vehicle diagnosis testing and information system VAS5051B in the Guided Fault Finding function Removing Remove instrument panel central tube remains installed Re f...

Page 135: ...ors page 30 Perform a basic setting on the A C after installing a new motor Refer to Vehicle diagnosis testing and information system VAS5051B in the Guided Fault Finding function Use output diagnostic test mode and basic setting to test the activation of A C electrical components if necessary for example allocation test using Vehicle diagnosis testing and information system VAS5051B in the Guided...

Page 136: ... rod D are color co ded they are colored blue for defroster door motor Reinstall all removed components in the opposite sequence while observing the following Install the wiring harness so that it cannot come in contact with any moving parts e g the actuating arm of the control motor Check Climatronic control module J255 DTC memory and erase any possible displayed malfunctions using Vehicle di agn...

Page 137: ... diagnostic test mode and basic setting to test the activation of A C heater electrical components if neces sary for example allocation test using Vehicle diagnosis testing and information system VAS5051B in the Guided Fault Finding function On the Audi TT with A C system both motors for left and right temperature doors are controlled via one characteristics curve depending on the programmed end s...

Page 138: ... bolts D Remove Left Temperature Door Motor B Loosen lever E on Left Temperature Door Motor from con necting rod F Installing Note Currently the lever E on the motor is gray and the connecting rod F black Reinstall all removed components in the opposite sequence while observing the following Install the wiring harness so that it cannot come in contact with any moving parts e g the actuating arm of...

Page 139: ...C system after installing a new control motor using Vehicle diagnosis testing and information system VAS5051B in the Guided Fault Finding function Using the functions Output diagnostic test mode and Basic setting the activation of A C system electrical components can be tested if necessary e g allocation test using Vehicle diagnosis testing and information system VAS5051B in the Guided Fault Findi...

Page 140: ...stall all removed components in the opposite sequence while observing the following Install the wiring harness so that it cannot come in contact with any moving parts e g the actuating arm of the control motor Check Climatronic control module J255 DTC memory and erase any possible displayed malfunctions using Vehicle di agnosis testing and information system VAS5051B in the Guided Fault Finding fu...

Page 141: ...nction Using the functions Output diagnostic test mode and Basic setting the activation of A C system electrical components can be tested if necessary e g allocation test using Vehicle diagnosis testing and information system VAS5051B in the Guided Fault Finding function On the Audi TT with A C system both motors for left and right temperature doors are controlled via one characteristics curve dep...

Page 142: ... the Guided Fault Finding function Perform a basic setting and output diagnostic test on the A C and check the DTC memory one more time Refer to Vehicle diagnosis testing and information system VAS5051B in the Guided Fault Finding function 5 9 Dust and Pollen Filter Note Dust and pollen filter change interval refer to Maintenance In tervals Rep Gr 03 There are different versions of the dust and po...

Page 143: ...nsulating mat B Cover the carpet with paper in the area under the dust and pollen filter Slide the cover B in direction of arrow C and remove it Note If retainers D no longer hold cover B may be secured with bolts A Remove dust and pollen filter A out of shaft B of air condi tioner heating Clean heating and A C unit via shaft B for example using a vacuum cleaner after removing dust and pollen filt...

Page 144: ...rent versions Be sure to use the right one Refer to the Electronic Parts Catalog With ignition switched on and Fresh Air Blower V2 actuated fresh air blower control module connects Positive from ter minal 4 of connector C to terminal 1 of connector B Fresh Air Blower speed is regulated by fresh air blower control mod ule via the ground connection between terminal 2 connector B and terminal 3 of co...

Page 145: ...ing properly after they are installed Check Climatronic control module J255 DTC memory and erase any possible displayed malfunctions using Vehicle di agnosis testing and information system VAS5051B in the Guided Fault Finding function Perform a basic setting and output diagnostic test on the A C heater and check the DTC memory one more time Refer to Vehicle diagnosis testing and information system...

Page 146: ... thus cannot be replaced separately Refer to Electronic Parts Catalog ETKA Remove the fresh air blower housing C from A C unit Disconnect connector D Installing Reinstall all removed components in the opposite sequence while observing the following Note When installing ensure fresh air blower is seated correctly in A C unit After installing check seating of fresh air blower housing in A C unit and...

Page 147: ...g seal are seated correctly If cover is not installed correctly water can run into the A C unit air intake shroud If the fresh air intake cover is damaged it must be replaced 5 13 Front Upper Body Outlet Temperature Sensors G385 G386 Left Front Upper Body Outlet Temperature Sensor G385 Right Front Upper Body Outlet Temperature Sensor G386 Note This temperature sensor is always installed on the dri...

Page 148: ... Clamps Up to 40 mm 3094 and Hose Clamps Up to 25 mm Diameter 3093 Compressed air gun commercially available Cooling System Tester V A G 1274 and corresponding adapter Switch off ignition Dissipate pressure in coolant circuit by opening cap at coolant expansion tank Refer to Engine Mechanical Rep Gr 13 General Information Note Depending on the engine and type of vehicle it may be necessary to loos...

Page 149: ...ion on a 3 2L MPI vehicle The procedure may be different on other 6 cylinder ve hicles Remove vacuum hose to brake booster arrow Procedure continued for all vehicles Remove components that block access to the coolant hoses A and B in engine compartment Refer to Engine Me chanical Rep Gr 13 Removal and Installation Note Depending on the engine and version of the vehicle it may be necessary to loose...

Page 150: ...olant hoses A and B from connections to A C unit heater core Refer to Engine Mechanical Rep Gr 13 Removal and Installation Connect a section of hose A onto upper connection Hold a container B under the lower connection C Using a compressed air gun carefully blow coolant out of heater core into container B Remove bolt A from connector flange B so that coolant pipes can be moved to remove heater cor...

Page 151: ...is not damaged Removing Remove 4 bolts A and remove cover B Note This illustration shows an A C unit with an auxiliary air heater heating element Z35 There are different versions of the cover B for vehicles with out or with auxiliary air heater heating element Z35 Refer to Electronic Parts Catalog ETKA If the lever C to the left temperature door is located unfavor ably so that the upper bolt A is ...

Page 152: ...d Installing Installation is carried out in the reverse order while noting the fol lowing Check the heater core seals A and B Note Seal may curl up on insertion if not correctly bonded on Cold air may flow past heater core if seal is damaged or not properly fitted Additional foam strips A are attached to the corners of the heater core B The foam strips A are supposed to stop any rattling noises wh...

Page 153: ...oolant Insert new seals A into connections of heater core D Push both coolant pipes C into heater core connections D Check seating of seals A again between coolant pipes C and connections of heater core D Secure both coolant pipes C and D with clamps B on heater core Tighten bolts on clamps A to 2 5 Nm Check seating of both clamps B after tightening bolts A clamps must enclose the flange on heater...

Page 154: ... po sition and state of heat protection insulation applied to coolant hoses if necessary not installed on all engine types Bleed cooling circuit Refer to Engine Mechanical Rep Gr 19 General Information Note When bleeding coolant circuit take special care to ensure complete bleeding of heater cores If there are still air bubbles in the heater core it may cause the customer to complain of insufficie...

Page 155: ... C compressor in this vehicle it may take a relatively long time for the pressure on the high pressure side to decrease This is because the expansion valve is cold and the pressure on the low pressure side increases quickly after shutting the compressor off then the expansion valve closes and the refrigerant flows slowly to the low pressure side Depending on the version of the high pressure sensor...

Page 156: ... Nm Installation is done is reverse order observe the following Replace O ring seal C Refer to 1 21 Refrigerant Circuit O rings page 41 Allocation refer to Electronic Parts Catalog Tighten high pressure sensor Mount the ribbed belt on the belt pulley Refer to Engine Mechanical Rep Gr 13 Removal and Installation 4 cylinder vehicles only 5 16 Instrument Panel Vents Special tools and workshop equipme...

Page 157: ...l the applicable instrument panel vent B out of instrument panel 5 17 Interior Temperature Sensor Fan V42 Note There is no Instrument Panel Interior Temperature Sensor G56 and no Interior Temperature Sensor Fan installed in the Clima tronic control module J255 for heater only Remove Climatronic control module for A C Refer to 1 9 Climatronic Control Module J255 page 31 Remove bolts A Pull Interior...

Page 158: ...operly assembled For ex ample if the refrigerant lines are not connected to A C compressor when the engine is running the A C compressor may heat up via internal heat generation so much that the A C compressor will be damaged The following illustration depicts an A C compressor for a ve hicle with 4 cylinder engine the allocation may deviate slightly for vehicles with other engines however the ref...

Page 159: ...ve On vehicles with this engine center noise insulation does need to be re moved On vehicles where the screws on the refrigerant line connec tion are not accessible when the A C compressor is installed remove the A C compressor from the bracket for example on 3 2L MPI vehicles Refer to 5 1 A C Compressor Removing From Bracket page 103 Remove this bracket for vehicles in which the refrigerant lines...

Page 160: ...ation Refer to 1 21 Refrigerant Circuit O rings page 41 Make sure the O ring seals are seated properly in the groove G on the respective refrigerant line Following attachment of refrigerant pipes to compressor and installation of compressor check routing of pipes They must be inserted in holders provided and not make contact with other components Evacuate refrigerant circuit and recharge again Ref...

Page 161: ...the design of the A C compressor itself note these oil capacities Too much oil in the circuit leads to higher pressures and reduces cooling performance of the system Too little oil may lead to lubrication problems in the compressor If a new compressor has been installed or new refrigerant oil has been put into the A C compressor for example after flushing refrigerant circuit the A C compressor mus...

Page 162: ...ant Lines page 154 Replace the O ring seals on opened connection points ver sion refer to Electronic Parts Catalog Remove the A C compressor from the bracket Refer to 5 1 A C Compressor Removing From Bracket page 103 or 5 2 A C Compressor Removing From Bracket page 106 After installing a new A C compressor or after charging com pressor with cold refrigerant oil such as after flushing refrig erant ...

Page 163: ...nt circuit is empty Prerequisite for the internal lubrication is residual refrigerant oil in A C compressor The engine may only be started when the refrigerant circuit is installed correctly For example if the refrigerant lines are not connected to A C compressor when the engine is running the A C compressor may heat up via internal heat generation so much that the A C compressor will be damaged A...

Page 164: ...cooler by loosening spring clips and hose clamps Refer to Engine Mechanical Rep Gr 21 Removal and Installation Loosen clamp 2 Disconnect electrical connector 4 Remove nut 3 and bolt 1 Remove intake downward Remove bolts arrows by releasing air ducts at left and right and tipping in direction of head lamps Tip top edge of charge air cooler back slightly Disengage charge air cooler from lower mounti...

Page 165: ...anical Rep Gr 21 Removal and Installation Install fan shroud Refer to Engine Mechanical Rep Gr 19 Removal and Installation Install front bumper cover Refer to Body Exterior Rep Gr 63 Removal and Installation Evacuate and fill refrigerant circuit Refer to Refrigerant R134a Servicing Rep Gr 00 Description and Operation A C Service Station Install remaining components Operate the A C system after fil...

Page 166: ... ignition Discharge refrigerant circuit Refer to Refrigerant R134a Servicing Rep Gr 00 Description and Operation A C Serv ice Station Remove the air intake leading to the air filter housing Refer to Injection and Ignition System Rep Gr 24 Removal and Installation Remove fan shroud Refer to Engine Mechanical Rep Gr 19 Removal and Installation Disconnect refrigerant lines from condenser Refer to 5 1...

Page 167: ...s arrows Remove condenser from cooler Remove condenser A downward Installing Tightening specification bolts for securing compressor to charge radiator 5 Nm Installation is done is reverse order observe the following Note The removed condenser contains refrigerant oil that must be re turned to the refrigerant circuit with the new condenser Refer to Refrigerant R134a Servicing Rep Gr 00 Removal and ...

Page 168: ...ervice Station Install remaining components Operate the A C system after filling the refrigerant circuit Re fer to 1 4 A C System Operating After Filling Refrigerant Circuit page 28 Note Note the information regarding operating the A C system after filling Refer to Refrigerant R134a Servicing Rep Gr 00 Description and Operation A C Service Station 5 18 5 Condenser Note The following describes remo...

Page 169: ...gnore arrow Remove bolts arrows by releasing air ducts at left and right and tipping in direction of head lamps Tip top edge of cooler back slightly Disengage cooler from lower mounting points by raising it Slide cooler in direction of engine Support cooler from below so that it cannot sink Note Do not bend or stretch lines or hoses as compressor and refrig erant lines hoses may be damaged Remove ...

Page 170: ...r cover Refer to Body Exterior Rep Gr 63 Removal and Installation Evacuate and fill refrigerant circuit Refer to Refrigerant R134a Servicing Rep Gr 00 Description and Operation A C Service Station Install remaining components Operate the A C system after filling the refrigerant circuit Re fer to 1 4 A C System Operating After Filling Refrigerant Circuit page 28 Note Note the information regarding ...

Page 171: ...orrectly inside the groove on the plastic screw A Keep the dryer cartridge D sealed in its air tight package as long as possible Open the package just before installing the dryer cartridge into the condenser The dryer cartridge ab sorbs moisture in a very short time and become unusable Install the filter E with the correct side into the condenser reservoir Take the dryer cartridge D out of its pac...

Page 172: ...ched reservoir refer to 5 18 11 Fluid Reservoir page 175 Removing Switch off ignition Discharge refrigerant circuit Refer to Refrigerant R134a Servicing Rep Gr 00 Description and Operation A C Serv ice Station Remove the condenser Refer to 4 cylinder 5 18 3 Condenser page 159 or 6 cylinder 5 18 5 Condenser page 164 Remove the adhesive sticker from the cap 1 Remove the cap 1 Remove the Seeger ring ...

Page 173: ...A to prevent dirt and moisture from getting in Installing Installation is done is reverse order observe the following Check the reservoir on the condenser 2 above the opening for dirt or damage to the sealing surfaces Replace the cap 1 and its seal the dryer cartridge and the filter strainer Coat the seal on the cap 1 lightly with refrigerant before in stalling Refer to 1 21 Refrigerant Circuit O ...

Page 174: ...ing arrow Install the cap 1 Install the condenser Refer to 4 cylinder 5 18 3 Condenser page 159 or 6 cylinder 5 18 5 Condenser page 164 Install remaining components Discharge and fill the refrigerant circuit Refer to Refrigerant R134a Servicing Rep Gr 00 Description and Operation A C Service Station Operate the A C system after filling the refrigerant circuit Re fer to 1 4 A C System Operating Aft...

Page 175: ...cement part Therefore with this kind of customer complaint about this vehicle where the dryer cartridge has to be replaced be sure to check whether the dryer cartridge can be used from some other repair kit for example whether the cartridge from the Audi A4 2008 condenser repair kit has been installed If it hasn t re place the entire condenser Refer to Electronic Parts Catalog ETKA and Refrigerant...

Page 176: ... cartridge F sealed in its air tight package as long as possible Open the package just before installing the dryer cartridge into the condenser The dryer cartridge absorbs moisture in a very short time and become unusable Take the dryer cartridge F out of its package and engage it on the filter element s hook C Install the dryer cartridge F and filter element C in the con denser reservoir Install ...

Page 177: ...s not damaged Check seal F it must be glued all around before inserting evaporator Place bracket C and seal insulation B onto connecting pipe of evaporator D and E Insert evaporator A into lower section of evaporator housing according to illustration Note After assembling both housing halves check seal insulation B for correct seating at pass through for both refrigerant lines D and E Check seatin...

Page 178: ...e the expansion valve If necessary loosen a refrigerant line that has no flexible piece of tubing out of the bracket so that the refrigerant line does not get damaged Removing Switch off ignition Discharge refrigerant circuit Refer to Refrigerant R134a Servicing Rep Gr 00 Description and Operation A C Serv ice Station Disconnect refrigerant lines from expansion valve Refer to 5 18 13 Refrigerant L...

Page 179: ...A C system change of adjusted control characteristic of expansion valve due to radiant heat Install refrigerant lines on the A C compressor Refer to 5 18 13 Refrigerant Lines Disconnecting and Connecting From Expansion Valve page 180 Discharge and fill the refrigerant circuit Refer to Refrigerant R134a Servicing Rep Gr 00 Description and Operation A C Service Station Install remaining components O...

Page 180: ...r removing and installing refer to 1 11 Dryer Cartridge page 33 The removed reservoir contains refrigerant oil that must be returned to the refrigerant circuit with the new reservoir Re fer to Refrigerant R134a Servicing Rep Gr 00 Removal and Installation Adjustment of oil quantity depends on nature of complaint If for example the fluid reservoir was damaged due to a vehicle accident no refrigeran...

Page 181: ...ange in MY 2007 the mounting was changed from a metal bracket at tached by screws to a plastic bracket held in place by a clip Tightening specification Bolts for securing fluid reservoir on condenser 10 Nm Installation is done is reverse order observe the following Note Coat the O ring seals lightly with refrigerant oil prior to instal lation Refer to 1 21 Refrigerant Circuit O rings page 41 Check...

Page 182: ...ion regarding operating the A C system after filling Refer to Refrigerant R134a Servicing Rep Gr 00 Description and Operation A C Service Station 5 18 12 Refrigerant Lines Disconnecting and Connecting from Condenser Note Different versions of the condenser are available depending on the vehicle version Refer to Electronic Parts Catalog ET KA 5 cylinder vehicles have a condenser A that has an addit...

Page 183: ...ective refrigerant line Following attachment check routing of refrigerant lines on condenser They must be inserted in holders provided and not make contact with other components Replace O rings E Version refer to Electronic Parts Cata log Check fitting pin G not installed at all connections and con nection F for damage and proper seating Tighten bolts C Tightening specification Bolts on refrigeran...

Page 184: ... Serv ice Station Remove components which hinder access to mounting points A on heat shield B in engine compartment Refer to En gine Mechanical Rep Gr 13 Removal and Installation Note For the sake of clarity the illustration shows the heat shield B with the engine removed Depending on the engine and type of vehicle it may be nec essary to loosen or remove various engine components Components that ...

Page 185: ...der vehicles Note The following describes removal and installation on a 3 2L MPI vehicle The procedure may be different on other 6 cylinder ve hicles Remove vacuum hose to brake booster arrow Components that must be loosened or removed on all vehicles Remove nuts arrows If present unclip line A from bracket Remove remaining nuts A Loosen heat shield B from mounting points lay it aside or remove it...

Page 186: ...tion Bolts A Refrigerant line expansion valve mounting screws 10 Nm Installation is carried out in the reverse order while noting the fol lowing Replace O ring seals D and E version refer to Electronic Parts Catalog ETKA Check fitted pin G installed in connection or in expansion valve not installed at all connections and sleeve H for dam age and proper seating Note Coat the O ring seals lightly wi...

Page 187: ...module J255 the Cli matronic control module cannot evaluate the signal from the sunlight photo sensor and the A C system is not regulated correctly On vehicles with no A C heater only there is no sunlight photo sensor installed A cover cap is installed on these vehi cles instead Switch off ignition Carefully pry cover A out of windshield defroster vent D Refer to Body Interior Rep Gr 70 Removal an...

Page 188: ... Sensor installed depending on version mounting opening in air distribution housing is not present or is sealed with sealing plugs Remove right center console trim Refer to Body Interior Rep Gr 68 Removal and Installation Disconnect the connector A Turn sensor B 90 and pull it out of A C unit Check seal C for proper seating when installing 5 20 2 Left Footwell Vent Temperature Sensor G261 Note On ...

Page 189: ...nnot be rotated or is not accessible be cause of other components B remove this component Refer to Body Interior Rep Gr 70 Removal and Installation This illustration depicts sensor B with instrument panel re moved With instrument panel installed the sensor B is visible from underneath when the footwell vent is removed part of sensor with temperature sensor is visible in air guide channel 5 20 3 Ri...

Page 190: ...ng points pro vided on housing using cable ties or on mounts so that it does not come into contact with moving components 2 Air Conditioner Unit Removing and instal ling refer to 5 3 A C Unit page 108 Heating and A C unit disassembling and as sembling refer to 6 2 A C Unit page 188 Disassembling and as sembling evaporator housing refer to 6 3 Evaporator Hous ing page 190 3 Auxiliary Air Heater Hea...

Page 191: ...Motor V113 Removing and installing refer to 5 8 5 Recirculation Door Motor V113 page 135 After installing check both control motors which must be held in position by this bracket if they are not installed free of play use some foam to rectify play if necessary attaching it to inside of mounting points of bracket Refer to 2 10 Air Flow Door Motor V71 Function page 62 14 Recirculation Door Motor V11...

Page 192: ...log The Fresh Air Blower Control Module is installed in the Fresh Air Blower Depending on the version both of these components can be either replaced separately or only together 20 Insulation Mat 21 Screw Clips 22 Right Temperature Door Motor V159 With Right Temperature Door Potentiometer Actuator G221 Lever color identification black Removing and installing refer to 5 8 6 Right Temperature Door M...

Page 193: ...log Make sure the correct Clima tronic control module J255 installed and then check the adaptation using Vehicle diagnosis testing and information system VAS5051B in the Guided Fault Find ing function Note 2 Screw 3 Air Guide Channel To Left Footwell Vent Different versions Refer to Electronic Parts Catalog ETKA A C system version with an opening for installing a temperature sensor 4 Heater Core F...

Page 194: ... refer to 5 18 10 Expansion Valve page 174 15 Evaporator Housing Disassembling and assembling refer to 6 3 Evaporator Housing page 190 16 Dust and Pollen Filter Removing and installing refer to 5 9 Dust and Pollen Filter page 138 Follow the replacement intervals Refer to Maintenance Intervals Rep Gr 03 With activated charcoal insert refer to 1 12 Dust and Pollen Filter with Activated Charcoal Inse...

Page 195: ...sing 2 Evaporator Check insulation it must be completely present Refer to 5 18 9 Evaporator page 172 Removing and Instal ling refer to 5 18 9 Evaporator page 172 3 Clip 4 Upper Section Of Evapora tor Housing 5 Screw 6 Seal Insulation Heat insulation for ex pansion valve Removing and instal ling refer to 5 18 9 Evaporator page 172 7 Bracket Removing and instal ling refer to 5 18 9 Evaporator page 1...

Page 196: ...is document Copyright by AUDI AG 7 Special Tools Hose Clamps Up to 40 mm 3094 and Hose Clamps Up to 25 mm diameter 3093 Compressed air gun commercially available Cooling System Tester V A G 1274 and corresponding adapter Hook 3438 Assembly Tool T10118 Locking Pin T10060 A Torque wrench V A G 1331 or 5 50 Nm equivalent Edition 04192011 Audi TT 2007 Heating Ventilation and Air Conditioning Edition 0...

Page 197: ...rts and specifications are made applicable to earlier models Therefore part numbers listed in this manual are for reference only Always check with your authorized Audi retailer parts department for the latest information Any time the battery has been disconnected on an automatic transmission vehicle it will be necessary to reestablish Transmission Control Module TCM basic settings using the VAG 15...

Page 198: ...Finger rings should be removed so that they cannot cause electrical shorts get caught in running machinery or be crushed by heavy parts Before starting a job make certain that you have all the necessary tools and parts on hand Read all the instructions thoroughly do not attempt shortcuts Use tools that are appropriate to the work and use only replacement parts meeting Audi specifications Makeshift...

Page 199: ...at automatically deploys an airbag in the event of a frontal impact The airbag is operated by an explosive device Handled improperly or without adequate safeguards it can be accidentally activated and cause serious personal injury To guard against personal injury or airbag system failure only trained Audi Service technicians should test disassemble or service the airbag system Do not quick charge ...

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