2013 Audi Q5 Service & Repair Manual
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Repair Manual
Audi Q5 2008 ➤
Heating, Ventilation and Air Conditioning
Edition 12.2008
Service
Service Department. Technical Information
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.
List of Workshop Manual Repair Groups
Repair Group
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 course, be observed.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2008 Audi AG, Ingolstadt A005Q502021
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.
Contents
87 - Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 A/C System Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Contact Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 A/C Components Controlled or Activated by Other Control Modules . . . . . . . . . . . . . . . . . . 4
1.6 Refrigerant Circuit, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.7 Refrigerant Circuit Discharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.8 Working on Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.9 Refrigerant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.10 Painting Vehicles with A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.11 Refrigerant Circuit O-ring Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.12 Air Quality Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.13 A/C System Control and Regulation Components Outside Passenger Compartment . . . . 12
1.14 A/C System Control and Regulation Components Inside Passenger Compartment . . . . . . 13
1.15 Dust and Pollen Filter with Activated Charcoal Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.16 Climatronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.17 Glove Compartment Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.18 A/C Unit and Air Intake Housing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.19 A/C Air Intake and Outlet Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.20 Air Conditioner, Levers and Connecting Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.21 A/C System, Operating after Filling Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.22 Evaporator, Cleaning with Ultrasonic HVAC Cleaning System VAS 6189 . . . . . . . . . . . . . . 22
2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.1 A/C System Components Outside Passenger Compartment Overview . . . . . . . . . . . . . . . . 25
2.2 A/C System Components Inside Passenger Compartment Overview . . . . . . . . . . . . . . . . 34
2.3 A/C Unit and Air Intake Housing Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.4 A/C Unit and Air Intake Housing Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.5 A/C Control Motor Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.6 Air Routing and Distribution Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.7 Air Routing in Air Intake Housing and A/C Unit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.8 A/C Unit Air Intake and Outlet Openings Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.9 Radiator Housing Temperature Door Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.10 Air Distributor Housing Doors and Partitions Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.11 Refrigerant Circuit Component Overview, Charged A/C System . . . . . . . . . . . . . . . . . . . . 63
2.12 Refrigerant Circuit Component Overview, Discharged A/C System . . . . . . . . . . . . . . . . . . 66
2.13 A/C Compressor Pulley Component Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.1 Checking Components Actuated by A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.2 A/C Pressure/Temperature Sensor, Checking Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.3 A/C Pressure and Temperature Sensor, Checking Pressure Signal . . . . . . . . . . . . . . . . . . 81
4.4 A/C Compressor Regulator Valve, Checking Activation Signal . . . . . . . . . . . . . . . . . . . . . . 82
4.5 A/C Compressor Regulator Valve, Electrical Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.6 Air Quality Sensor, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.7 A/C Cooling Output, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.8 Heat Output and Temperature Door Activation, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.1 Instrument Panel and Rear Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.2 Sunlight Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Audi Q5 2008 ➤
Heating, Ventilation and Air Conditioning - Edition 12.2008
Contents i
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.
5.3 Dust and Pollen Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5.4 Condensation Water Drain Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
5.5 Passenger Compartment Forced Air Extraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
5.6 Plenum Chamber Water Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5.7 Fresh Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5.8 A/C Pressure/Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.9 Outside Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5.10 Air Quality Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
5.11 A/C Compressor Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.12 Climatronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
5.13 Interior Temperature Sensor Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
5.14 A/C Unit Air Intake Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
5.15 Right Footwell Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.16 Left Footwell Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.17 Air Intake Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.18 Fresh Air Blower Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5.19 Fresh Air Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5.20 Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5.21 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
5.22 Left Radiator Housing with Temperature Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
5.23 Right Radiator Housing with Temperature Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
5.24 A/C Unit Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
5.25 Refrigerant Line Quick Release Couplings, Disconnecting and Connecting . . . . . . . . . . . . 204
5.26 Refrigerant Lines with Inner Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
5.27 Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
5.28 Refrigerant Lines to Condenser, Disconnecting and Connecting . . . . . . . . . . . . . . . . . . . . 212
5.29 Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
5.30 Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
5.31 Evaporator, A/C Unit Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
5.32 A/C Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
5.33 Refrigerant Lines to Compressor, Disconnecting and Connecting . . . . . . . . . . . . . . . . . . . . 236
5.34 A/C Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
6 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
6.1 A/C Unit Air Intake Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
6.2 Evaporator Housing Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
6.3 Retaining Plate with Footwell Door Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
6.4 A/C Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
6.5 Retaining Plate with Right Footwell Door Motor and Center Vent Motor . . . . . . . . . . . . . . 255
6.6 Retaining Plate with Left Footwell Door Motor and Center Vent Motor . . . . . . . . . . . . . . . . 256
6.7 A/C Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
7 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Audi Q5 2008 ➤
Heating, Ventilation and Air Conditioning - Edition 12.2008
ii Contents
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.
87 – Air Conditioning
1 General Information
⇒ “1.1 Safety Precautions”, page 1
⇒ “1.2 General Repair Information ”, page 2
⇒ “1.3 A/C System Additional Information”, page 3
⇒ “1.4 Contact Corrosion”, page 3
⇒ “1.5 A/C Components Controlled or Activated by Other Control
Modules”, page 4
⇒ “1.6 Refrigerant Circuit, Servicing”, page 5
⇒ “1.7 Refrigerant Circuit Discharging”, page 5
⇒ “1.8 Working on Refrigerant Circuit”, page 6
⇒ “1.9 Refrigerant Capacities”, page 7
⇒ “1.10 Painting Vehicles with A/C System”, page 8
⇒ “1.11 Refrigerant Circuit O-ring Seals”, page 8
⇒ “1.12 Air Quality Sensor”, page 9
⇒ “1.13 A/C System Control and Regulation Components Outside
Passenger Compartment”, page 12
⇒ “1.14 A/C System Control and Regulation Components Inside
Passenger Compartment”, page 13
⇒ “1.15 Dust and Pollen Filter with Activated Charcoal Insert”,
page 14
⇒ “1.16 Climatronic Control Module”, page 16
⇒ “1.17 Glove Compartment Cooling”, page 18
⇒ “1.18 A/C Unit and Air Intake Housing Components”,
page 19
⇒ “1.19 A/C Air Intake and Outlet Routing”, page 20
⇒ “1.20 Air Conditioner, Levers and Connecting Elements”, page
20
⇒ “1.21 A/C System, Operating after Filling Refrigerant Circuit”,
page 21
⇒ “1.22 Evaporator, Cleaning with Ultrasonic HVAC Cleaning
System VAS 6189”, page 22
1.1 Safety Precautions
The following safety measures should be observed for this refrig‐
erant system (additional guidelines apply in individual countries).
If is necessary to open the refrigerant circuit during service work,
discharge the refrigerant circuit first, refer to
⇒ “1.7 Refrigerant Circuit Discharging”, page 5 . In doing so,
the utmost care is to be taken to avoid contact with the liquid re‐
frigerant or refrigerant vapors. Should refrigerant nevertheless
escape, avoid inhaling the resultant refrigerant/air mixture.
Extraction systems are therefore to be switched on and use safety
equipment consisting of both rubber gloves and protective gog‐
gles.
Audi Q5 2008 ➤
Heating, Ventilation and Air Conditioning - Edition 12.2008
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