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Technical Service Bulletin
87 Air conditioning system: cooling output insufficient, leak on air conditioning system evaporator
United States 444 Volkswagen of America, Inc. (6444)
[Status | Released for publishing
Release date [Jul 22, 2025
New customer code
Object of complaint Complaint type [Position|
climate control -> ventilation, air distribution -> ventilation with functionality -> no function
fresh air blower -> ventilation with fresh air blower level 2 y

. a . . . . service: process -> with complaint
vehicle service -> inspection, maintenance -> field activity confirmation
climate control -> ventilation, air distribution -> ventilation with functionality -> no function right
fresh air blower -> automatic air quantity regulation y 9

. . component, automotive fluids ->
climate control -> cooling -> condenser damaged
vehicle service -> vehicle diagnosis -> Guided Fault Finding control modules, services -> without
(GFF) OBD entry
vehicle service -> inspection, maintenance -> performing a service: process -> with complaint
service confirmation
engine -> cooling, lubrication -> engine coolant temperature functionality -> irregular
regulation
climate control -> operation, climate control -> display control . fy pee
head for A/C system -> climate control operating unit A/C button functionality -> too difficult to move
engine -> cooling, lubrication -> engine coolant temperature F by
regulation functionality -> faulty
climate control -> ventilation, air distribution -> ventilation with noises, vibrations -> noise
fresh air blower -> ventilation with fresh air blower level 1 ,
climate control -> ventilation, air distribution -> ventilation with . . .
‘ ae - functionality -> irregular left

fresh air blower -> automatic air quantity regulation
climate control -> cooling -> refrigerant filler valve (high pressure) missing components -> cover cap | |
climate control -> heating, cooling -> manual climate control ‘ . .
mode -> maximum cooling (LOW) functionality -> no function
vehicle service -> vehicle diagnosis -> Guided Fault Finding control modules, services -> with fault
(GFF) stored in the DTC memory
climate control -> heating, cooling -> automatic climate control functionality -> cannot be switched
mode (AUTO) -> climate control deactivation (OFF) off/deactivated
Vehicle data

A5 Coupe, A5 Sportback, A5 Cabriolet

Sales types

Final drive code
ess jaov7fa |
ess jaorsfa |
pss aovfa |
[rss [zoofa |
jess jzozifa |
[rst |aozfa |
[rss jaozsfa |
[rss jaozfa |
[rss Jaozsfa J
Q5, Q5 Sportback

Sales types

ey zovfa fT
ify aorsfa |
fy faorfa |
[ry Jaozofa [|
ev faozfa |
[rvs faozfa [|
rv faozsfa |
[rvs [zozafa |
[rvs jzosfa fF
Audi e-tron GT, Audi RS e-tron GT

Sales types

Final drive code
[rex faozfa [|
[rex jaozsfa |
[res [zozafa |
[res jaosfa ff
A4, A4 Allroad

Sales types

jew: faorfa |
jew: faozofa [|
jew: faozifa |
jew: faozfa |
jew: faozsfa |
jew: jaozafa |
jaw: jaosfa fF
A6, A6 Allroad, RS 6 Avant

Sales types

faa fowfa | OP Cd Cid
(sar faoaofa [| SiS SC C—*S
jaar faozifa ft
[aar_[ozzfa ft
jaar fzozsfa |
jaar _faozafa |
laa Jaovsfa J
AT

Sales types

ac owls | PO
‘ace faozofa fd
jax faozifa |
jac: aoa |
jax: faozsfa [|
jax: faozafa |
lacs Jaozsfa J
A8&

Sales types

av owe | OPO
jan aozofa |
jan faozyfa fT
lant faozfa [
jan faozsfa |
jan faozafa
lant [aosfa fF

Q7, Q8, SQ8, RSQ8

Sales types

Final drive code
jam aorgfa |
jam aov7fa |
jam forsfa PR
jam forsfa PR
lame [aozofa PR
jaw faoztfa |
jam aozfa [|
jam faozsfa |
jam faozafa
lame Jaozsfa [
Q4 e-tron

Sales types

rar faozsfa |
rar faozfa |
[rar Jaozsfa [|
Documents
training_module_atp_611_05_2022_sost_leak_test_on_the_refrigerant_circuit_r134a_r1234yf_and_r744.pdf
vdm2064077_1.doc

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Technical Service Bulletin Transaction No.: 2064077/7

87 Air conditioning system: cooling output insufficient, leak on air conditioning system Release date: Jul 22, 2025

evaporator . ,

Condition

REVISION HISTORY

Revision [ote urpose

' | 01/23/2025 Revised Warranty (Add GFF allowance)

5 07/24/2024 Revised header (Remove TT, Q3, A3, R8 and e-tron models, add MY 2025)
Revised Technical Background (Change problem description and images)
Revised Production Solution (Restate solution)
Revised Service (Restate service, remove images, add photo documentation
requirement)
Revised Warranty (Change labor operation, remove GFF allowance)

Customer states:

+ The air conditioning does not cool the interior.

+ The cooling output of the air conditioning system is insufficient.

Workshop findings:

+ The customer statement can be reproduced.

+ The refrigerant circuit is not filled with the required amount of refrigerant.

Technical Background

1. An insufficient amount of refrigerant is usually Klimagerat/Verdampfer
caused by leaks in the refrigerant circuit. \ fi
_ 4 1 ka
On the vehicles listed in this TSB, the evaporator «4 “
of the air conditioning system is a potential jy Pi
source of a leak. It is fitted in the air conditioning eS 4 : ss
unit and is not easily accessible from outside ee | : r : 7
(Figure 1). * Le Cy | ’
, y=
a hI ’
aL)
) " 2 7
} a a,
Figure 1. Air conditioning unit / evaporator.
2. Without direct access to the evaporator, the following are possible ways to detect a leak in the evaporator:
3. Electronic leak detector: x ow { -
. ay fj <
Check whether the electronic leak detector finds \ S if < ai
refrigerant on the center vents (Figure 2). To do | . en }
this, select the following air conditioner settings: er f
Blower on lowest level and air distribution setto = ‘N > }
dash panel vents. ~~ i
ine aaa 7 —
: { = }
We
= “NY
Figure 2. Electronic leak detector at center vents.
4. Leak detection additive:
If a leak detection additive is put into the
refrigerant circuit, deposits of the additive will
appear on the condensation drain after the air
conditioner has been operated at a high load for
a sufficient time (Figure 3).
Figure 3. Leak detection additive at condensation drain..

5. You can also check this on the vehicle ey
underbody (Figure 4). ae
- a
z > ”
Figure 4. Leak detection additive under vehicle.
6. Leak test for refrigerant circuits R134a, R1234yf and R744 with forming gas (calibration gas):
For further information on the exact procedure and the tools required to carry out the leak test, please refer to
the Training module ATP 611 05_2022: SoST - Leak test on the refrigerant circuit R134a, R1234yf and R744 in
the attachments of this TSB.
G Attachments
epa' tructions pdf
Figure 5. Attachments tab in ElsaPro. Figure 6. Attachments location in Elsa2Go.
Mewes
For vehicles with refrigerant R744 only the “Leak test with forming gas” method is allowed.
a
“10 es
Should the evaporator for the Q5 be ae ee ee
confirmed leaking by way of this - 7 = Sa 7
diagnostic procedure and replacement of HT pwr =<
the evaporator is performed it is necessary Aes 4 M4 oa — ae
to loosen and refasten the Relay and Fuse a iF Fok (aN S ,
Carrier 3 -SR3- (shown in figure 5, position ij _.@=~ = 3
1) in the course of the repair. During wu = s e
reassembly of the vehicle, it is critically ay SWie — et NOE
important that this relay and fuse carrier is \" > dan? pa ag Ay aN be NN
reinstalled in its correct original position. eZ ES ie ray) nS
Failure to reinstall the Relay and Fuse @ if A a ote uN - \\F an
Carrier 3 precisely will result in water PLS 3 Posie isi i; yaa ®
intrusion and subsequent component Uh] pes aS lO FSS
damage. v tg Pe DO Nah Pen) 7

Figure 7. Relay and fuse carrier 3 -SR3-.
Production Solution
Gradual introduction of optimized production process in series production.
Service
If a leak is determined on the evaporator, replace the evaporator.
Important: Check the refrigerant circuit for leaks after completing the work.
Any further leaks must be dealt with according to the instructions in the Workshop Manual.
When billing, please always attach photos/videos that clearly shows the complaint to DOC-IT. To ensure a reference
to the vehicle, the image/video must:
Include the VIN and date.
Must not be edited.
Should be in focus and taken with sufficient light. A high resolution is not necessary.
If appropriate, please mark the location of the problem so that parts analysis has a clear reference to the complaint.
Please ensue that the photo documentation does not show any persons and/or face, license plates, or customer
data.
Warranty
Claim Type: + Ifthe vehicle is outside of any warranty, this Technical Service Bulletin is
informational only.
Damage Code: 0050
Labor Operations: Check evaporator 8760 0199 Time necessary for
diagnosis supported
by punch time
Remove and install evaporator 8760 19xx See SRT with
associated
operations
GFF / Guided Functions 0150 0060 Time stated on the
diagnostic protocol
Claim Comment: As per TSB 2064077/6
All warranty claims submitted for payment must be in accordance with the Audi Warranty Policies and Procedures
Manual. Claims are subject to review or audit by Audi Warranty.
Additional Information
All part and service references provided in this TSB (2064077) are subject to change and/or removal. Always check
with your Parts Department and/or ETKA for the latest information and parts bulletins. Please check the Repair
Manual for fasteners, bolts, nuts, and screws that require replacement during the repair.
©2025 Audi of America, Inc. All rights reserved. The information contained in this document is based on the latest
information available at the time of printing and is subject to the copyright and other intellectual property rights of

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