Condenser HVAC: Service and Repair

Condenser

• The radiator and condenser may have small indentations on the fins even when installed correctly. It is not damage. Do not replace the radiator or condenser because of those small indentations.

• Slight deformations on the side securing straps on the condenser (for example, due to an accident), can result in an unparalleled flow from the condenser and radiator; this can be resolved by pulling the straps back as long as the function/condenser sealing is not impaired. The straps on the condenser do not need to be replaced if there are small deformations.

• A slight bending of the condenser (up to 4 mm) is permissible as long as there is sufficient distance (minimum 4 mm) between the condenser and the radiator and the function/sealing of the condenser (of the refrigerant circuit) is not impaired. The condenser does not have to be replaced if there are slight deformations.

• Condenser is available in different versions, depending on version of vehicle. Refer to Electronic Parts Catalog.

Removing

- Switch off ignition.

- Drain the refrigerant circuit.

- Remove the lock carrier cover and the front bumper cover.

- Remove the front impact member as required (for example for vehicles with 8 cylinder TFSI engine).

- Remove both air ducts - A - for the air intake of the engine.






- Remove the bracket for the signal horn and dual tone horn (H1) - B - from the lock carrier.

- Remove air duct - C -.

- Remove bolts - B -.

- Unlock retaining tabs - F - and remove air duct - D - and - E -.

- Disconnect electrical harness connector - A - from the A/C pressure/temperature sensor (G395).






- Remove the power steering oil cooler- A - from the condenser and press it to the side (or to the bumper carrier - B - if necessary).






• Power steering oil cooler - A - is available in different versions depending on the vehicle.

- Remove the refrigerant lines from the condenser, refer to => [ Condenser Refrigerant Lines ] Condenser Refrigerant Lines.

- Release mounts - D - for brackets - C - of condenser - E - and remove condenser - E - in an upward direction - direction of the arrow -.

Installing

Installation is done is reverse order, observe the following:

• The removed condenser contains refrigerant oil that must be returned to the refrigerant circuit (with the new condenser).

- Install the refrigerant lines to the condenser, refer to => [ Condenser Refrigerant Lines ] Condenser Refrigerant Lines.

- Install the power steering oil cooler cooling coil.

- Install the cover on the lock carrier.

- Evacuate and fill the refrigerant circuit.

- Install the remaining components.

- Check the event memory of the Climatronic control module (J255) , and erase any displayed malfunctions using the Vehicle Diagnostic Tester in the "Guided Fault Finding" function.

- Operate the A/C system after filling the refrigerant circuit, refer to => [ A/C System Operating After Filling Refrigerant Circuit ] A/C System Operating After Filling Refrigerant Circuit.

• Note the information regarding operation of the A/C system after filling.