Technical Service Bulletin
HVAC refrigerant leakage suspected or reports of a damp/musty smell within the cabin Diagnosis guidelines

Topic

Australia E04 Bentley rest Asia and Australia (6E04),China 723 Volkswagen (Anhui)
Automotive CO (6723),China 796 VW Import Comp. Ltd (Vico), Beijing (6796),Germany E02
Market area Bentley rest Europe (6E02),Japan E03 Bentley Japan (6E03),Korea, (South) E08 Bentley
South Korea (6E08),United Arab Emirates E06 Bentley Middle East and Africa (6E06),United
Kingdom E01 Bentley UK (6E01),United States E05 Bentley USA and rest America (6E05)
Brand

Bentley

Transaction
2069806/7
No.
Level

EH

Status

Released for publishing

Release
date

Sep 8, 2025

New customer code

Object of complaint

Complaint type

climate control -> cooling

component, automotive fluids

climate control -> heating, cooling -> manual climate control mode functionality -> no function
climate control -> heating, cooling -> automatic climate control
mode (AUTO)

functionality -> cannot be
activated

New workshop code

Object of complaint

Complaint type

Position

climate control -> cooling -> evaporator leaks -> connection leaks front
climate control -> cooling -> evaporator leaks -> not watertight

front

Vehicle data
All Models
Sales types

Type MY

Brand Designation Engine code Gearbox code Final drive code

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2004 E

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2005 E

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2006 E

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Position

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2007 E

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2008 E

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2009 E

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2010 E

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2011 E

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2012 E

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2013 E

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2014 E

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2015 E

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2016 E

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2017 E

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2018 E

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2019 E

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2020 E

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2021 E

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2022 E

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2023 E

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2024 E

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Documents
Document name
master.xml
attachment2069806.pdf
hvacword.doc

Transaction No.:

Technical Service Bulletin
HVAC refrigerant leakage suspected or reports of a damp/musty smell within the
cabin - Diagnosis guidelines

2069806/7
Release date: Sep 8,
2025

Condition
HVAC not cooling / HVAC cooling less than expected / HVAC refrigerant leakage confirmed
Or
The customer reports a damp/musty smell within the cabin Note: For this scenario please see the pre
requisites below

•

Should no HVAC leak be evident and a damp/musty smell has been reported/identified the operative
should first confirm that water is not leaking into the cabin please refer to all VIN applicable TPI’s

•

Should there be no water leaks evident, the operative should check the HVAC and body drains for
blockages, in the event the drains are blocked the drains must be unblocked, once this has been
completed the operative should confirm if the damp/musty smell is still evident

Hint: Should the damp/musty smell still be evident after the drains have been cleaned and/or water leaks
have been repaired, the operative should consider the smell could be related to accumulation of algae,
fungus and/or mold on and around the evaporator, in this scenario the operative must raise a DISS query
requesting permission to clean the HVAC system
NOTICE
In the event that HVAC cleaning products are required, these MUST be sourced locally. Before using the
cleaner the operative must inform the customer of the product which will be used, a neutral fragrance
cleaner should be used as the customer may not like the smell of the cleaner should a fragranced product
be used.
Please ensure all supporting information is included within the DISS query when requesting permission to
clean the HVAC system including clear photographs and/or videos showing the reported issue, should the
required information not be supplied the warranty claim could be cancelled
The retailer can conduct the cleaning process or a local HVAC specialist may be used to conduct the
cleaning process, however this would require permission via DISS before being conducted
CAUTION
Do Not replace the evaporator for this issue, if the issue is still evident after the HVAC system has been
cleaned, the operative must raise a new DISS query or respond via the existing query
NOTICE
In the event that no HVAC leaks/issues were found and the damp/musty smell was evident resulting in the
requirement to clean the HVAC system, this would not be covered by warranty and must be paid by the
customer as this related to a maintenance issue and not a HVAC functionality issue

Technical Background
CAUTION
DO NOT UNDER ANY CIRCUMSTANCES INSTALL TRACER ADDITIVES INTO THE HVAC SYSTEM

Before conducting any work on the HVAC system the operative MUST refer to the following within Rep.Gr 87
•

Refrigeration system - Safety and general information

It has been observed that some HVAC components have been incorrectly diagnosed and replaced, after the
components were returned for inspection no faults were found
CAUTION
The leaks in these scenarios were repaired after component replacement however as the parts were not
at fault the actual fix of the leak would have been resolved by replacing O-rings only

NOTICE
IMPORTANT NOTICE: Before proceeding the operative should check to confirm there are no VIN
applicable HVAC/refrigerant leak related TPI’s
Workshop diagnosis based on the customer complaint could be as follows:
•

HVAC is not cooling or the HVAC is not effective due to leakage of the refrigerant

•

Refrigerant recovered from the system shows a low volume or no refrigerant at all

•

Leakage is suspected from the compressor as no other leakage source was found
NOTICE

please refer to the examples shown below (Figures 1,2 and 3) of leaks found on the HVAC compressor

Figure 1

Figure 2

Figure 3

Figure 4
In the event the HVAC sniffer tool traces a HVAC leak from any of the outlets (Figure 4)
Or
A complaint is received that refrigerant is evident within the cabin.
NOTICE
The operative MUST first ensure that a leak is not evident within the plenum chamber or around the centre
console (Figures 5 and 6) as refrigerant could be leaking into the plenum chamber/cabin, and recirculated
back into the cabin which could lead to misdiagnosis and/or incorrect part replacement.

Figure 5

Figure 6

In the event that leakage is suspected from the thermal expansion valve (TXV) the thermal expansion valve
can be replaced when the HVAC unit is fitted within the car
•

The operative must first refer to the attached flow chart before proceeding with any diagnosis or parts
replacement

TIP: The attached document is for assistance in diagnosing the HVAC leak for issue relating to damp/musty
smells within the cabin please refer to the Customer statement/Workshop findings section of this TPI
•

Before conducting any work on the HVAC system the operative MUST refer to the following within Rep.
Gr 87

•

Refrigeration system - Safety and general information

•

Refrigerant oil - Special instructions

•

Refrigeration system - To discharge and charge

IMPORTANT TIP: When a HVAC line/connection has been opened the operative MUST always cap/bung
the applicable port using a suitable cap/bung
CAUTION
In the event the evaporator or compressor is suspected to be at fault the operative must raise a Technical
DISS query before conducting any further work ensuring the following is attached.
– Refill the HVAC system with refrigerant and inspect thoroughly for any additional sources of leakage.
– Photograph and video of the refrigerant quantity and the actual leakage location.
– If no further leaks are identified and the evaporator or compressor remains to have a suspected fault,
escalate the case by raising a DISS to 2nd level support for further investigation. For 2nd Level DISS
Support – Required Dealer Actions Below.
– Extract MVBs (Measured Value Blocks) from System Address – 0008 (Climate Control Module).
– Refer to the image below for the specific Measured Value Blocks (MVBs) that must be extracted and
submitted.

CAUTION
DO NOT replace the dryer if the evaporator is being replaced unless it is advised in via a technical DISS
query. This is to protect the HVAC parts from moisture & foreign elements getting into the system. Always
refer to the procedure that has been provided in ElsaPro.
Or
In the event the evaporator or compressor is not suspected as being at fault and the issue can be
successfully diagnosed and repaired, please raise a non-technical DISS query stating the issue which was
evident and how the issue was resolved

Revision History – TPI 2069806/7

Technical background modification – To include additional HVAC servicing procedures. Specifically
refrigerant refill, leak inspection, and media documentation. Clarified escalation criteria and outlined required
diagnostic data measured value blocks (MVBs from Address 0008) for DISS submission to 2nd Level
Support.

Production Solution
-

Service
Refer to the Technical background section

Warranty
Time to conduct the initial checks within the Measure section
Warranty Type

110 or 910

Damage Service Number

87 01

Damage Code

00 50

Labour operation code

87 01 01 20

Time

50 TU

In the event that any parts are required to be replaced please refer to the warranty accounting instructions
with Elsa pro this is due to the numerous vehicle specification and symptom scenarios
NOTICE
In the event that no HVAC leaks/issues were found and the damp/musty smell was evident resulting in the
requirement to clean the HVAC system, this would not be covered by warranty and must be paid by the
customer as this related to a maintenance issue and not a HVAC functionality issue
NOTICE
Please ensure all supporting information is included within the DISS query including clear photographs and
/or videos showing the reported issue, should the required information not be supplied the warranty claim
in some cases could be cancelled
NOTICE
All HVAC related claims will be checked by the Warranty team, any claims which are not deemed as
applicable will be cancelled
– In the event that parts are replaced parts without the required attachments or the parts are found to be
not at fault warranty claims will be liable for rejection

Required Parts and Tools
Refer to the ETKA parts catalogue for any additional parts requirements
NOTICE
In the event that HVAC cleaning products are required, these MUST be sourced locally. Before using the

cleaner the operative must inform the customer of the product which will be used, a neutral fragrance
cleaner should be used as the customer may not like the smell of the cleaner should a fragranced product
be used

Take photographs/videos to
showing a reduction or /no HVAC
Refrigerant

Confirm leakage source by HVAC
sniffer tool or leak detection
spray/Soapy water

Leakage Suspected at Evaporator
as not found in other part

Leakage

Other than Evaporator

Source

Replace affected part
Confirm Evaporator Leakage
Raise a Technical DISS Query requesting permission to
replace the evaporator

Yes

Replace Evaporator

INTERNAL

Leakage
present on
Evaporator

No

Do not Replace
Evaporator, continue
with further diagnosis