SM 47.c

Service
Audi A6 1998 ➤
Heater
Edition 10.1997
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.
Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Audi A6 1998 ➤
Heater
Repair Group
01 - Self-diagnosis, Electrical check
80 - Heating
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.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt A0056007820

Audi A6 1998 ➤
Heater - Edition 10.1997
Contents
01 - Self-diagnosis, Electrical check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1 Self-diagnosis of heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 Self-diagnosis of heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.3 Technical data for self diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.4 Test requirements for self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.5 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2 Connecting vehicle diagnostic, measuring and information system VAS 5051 or fault reader
V.A.G 1551 and selecting function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2.1 Connecting vehicle diagnostic, measuring and information system VAS 5051 or fault reader
V.A.G 1551 and selecting function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3 Interrogating fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.1 Interrogating fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4 Fault table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.1 Fault table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
5 Final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
5.1 Final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
6 Basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
6.1 Basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
7 Erasing fault memory, ending output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
7.1 Erasing fault memory, ending output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
8 Reading measured value block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
8.1 Reading measured value block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
9 Electrical test of heater controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
9.1 Electrical
permitted unless authorised by AUDI AG.test ofAG
AUDI heater
does notcontrols
guarantee or. accept
. . . .any
. . liability
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
10 Electrical test of rear window heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
10.1 Electrical test of rear window heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

11 Electrical test of additional heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
11.1 Electrical test of additional heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
80 - Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
1 Heater components on vehicle exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
1.1 Heater components on vehicle exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
1.2 Checking vent frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
1.3 Removing and installing dust and pollen filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
2 Heater components in vehicle interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
2.1 Heater components in vehicle interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
2.2 Removing and installing heater controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
2.3 Removing and installing Bowden cable for left-hand temperature flap . . . . . . . . . . . . . . . .39
2.4 Remoiving and installing Bowden cable for right-hand temperature flap . . . . . . . . . . . . . . . .41
2.5 Removing and installing series resistor -N24 for fresh air blower . . . . . . . . . . . . . . . . . . . .42
2.6 Removing and installing fresh air blower -V2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
2.7 Removing and installing defrost flap positioning motor -V107 . . . . . . . . . . . . . . . . . . . . . . . .43
2.8 Removing and installing central flap positioning motor -V70 . . . . . . . . . . . . . . . . . . . . . . . .43
2.9 Removing and installing fresh/recirculated air flap positioning motor -V154 . . . . . . . . . . . .44
2.10 Making special tool for removing dash-panel vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
2.11 Removing and installing centre dash-panel vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
2.12 Removing and installing left-hand dash-panel vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
2.13 Removing and installing windscreen defroster vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
2.14 Removing and installing right-hand dash-panel vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
2.15 Removing and installing left-hand and right-hand side window defroster vents . . . . . . . . . .48
2.16 Removing and installing heater element for additional heater -Z35 . . . . . . . . . . . . . . . . . . . .48
Contents i
Audi A6 1998 ➤
2.17 Remoiving and installing heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

3 Changes to the heating system since 09.98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
3.1 Changes to the heating system since 09.98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
3.2 Visible differences between heater types "1" and "2" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
4 Dismantling and assembling heater controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
4.1 Dismantling and assembling heater controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
5 Air duct in heater and in vehicle interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
5.1 Air duct in heater and in vehicle interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
5.2 Air duct in heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
5.3 Air ducts in vehicle interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
6 Removing and installing heater (complete) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
6.1 Removing and installing heater (complete) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
7 Dismantling and assembling heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
7.1 Dismantling and assembling heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
8 Dismantling and assembling air distributor housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
8.1 Dismantling and assembling air distributor housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
9 Dismantling and assembling air duct with intake housing . . . . . . . . . . . . . . . . . . . . . . . . . .78
9.1 Dismantling and assembling air duct with intake housing . . . . . . . . . . . . . . . . . . . . . . . . . .78
ii Contents
Audi A6 1998 ➤
01 - Self-diagnosis, Electrical check
1 - Self-diagnosis of heating system

1.1 - Self-diagnosis of heating system
Note:
The control functions of the heating system remain in operation during self-diagnosis.
1.2 - Function
Thermotronic control unit -J214 (fitted in the heating controls) receives information from electrical and electronic
system components (signal senders), and then processes this information according to the programmed spec‐
ifications.
The output signals from the control unit then regulate the electrical components (control elements).
To enable the cause of the fault to be determined quickly if a component fails or if there is an open circuit, the
operating and display unit
-E87 is equipped with a fault memory which can be interrogated using fault reader V.A.G 1551 or vehicle
diagnostics system VAS 5051 or vehicle system tester V.A.G 1552.
Any faults which occur in the monitored sensors / components are stored in the fault memory with details of
the type of fault.
Always start fault finding by initiating self-diagnosis and interrogating the stored information with the
fault reader V.A.G 1551
the
vehicle system tester V.A.G 1552
or the
vehicle diagnostic, testing and information system VAS 5051.
The fault information displayed is used to refer to a fault table with notes on the possible causes for directed
repair measures.
Notes on fault handling:
◆ If a fault condition exists for more than a predetermined period, the fault is stored as a static fault. If the fault
situation has ceased to exist for a specific time, the fault becomes a sporadic fault. This process is repeated
constantly. Sporadically occurring faults are also marked as such by SP on the right of the display.
◆ The control unit -J214 will only record a sporadic fault as a permanent fault if it is still present after a certain
period of time, or if several unsuccessful attempts have been made to rectify it (for example, if the position
of the rotary control for air distribution has been changed 5 times but the positioning motor has not moved).
◆ A stored fault which no longer occurs after a certain period of time (e.g. after the ignition has been switched
on and off 15 times) is automatically erased from the fault memory.
1.1 - Self-diagnosis of heating system 1

Audi A6 1998 ➤
Self-diagnosis is only possible using fault reader V.A.G 1551 (mode 1, "Rapid data transfer") V.A.G 1552, or
VAS 5051.
Self-diagnosis is not restricted to final control diagnosis and the storage, interrogation and erasing of faults. It
also has basic setting and control unit identification functions.
Mode 2 ("Flash code output") is not available for the heating/air conditioner electronics. Modes 3 ("Self-test")
and 4 ("Dealership code") only concern fault reader V.A.G 1551 and vehicle system tester V.A.G 1552, and
are described in the relevant operating instructions.
Note:
The following description only refers to the self-diagnosis procedure carried out using the fault reader V.A.G
1551.
Self-diagnosis can also be performed in the same manner with VAS 5051 or V.A.G 1552. It is advisable to print
out any existing faults after the fault memory has been interrogated so that a record of any faults is available if
queries should arise at a later stage.
If the fault reader was read out with V.A.G 1552, it is advisable, before the fault memory is erased, to connect
V.A.G 1551 or V.A.S 5051 and to print out the existing faults (V.A.G 1552 does not have a printer).
1.3 - Technical data for self diagnosis
▪ Memory Non-volatile memory

▪ Data output Rapid data transfer "Mode 1"
▪ Self-diagnosis AC/heating electronics "Address word 08"
- Interrogate control unit version Function 01
- Interrogate fault memory Function 02
- Perform final control diagnosis Function 03
- Perform basic setting Function 04
- Erase fault memory Function 05
- End output Function 06
- Read measured value block Function
Protected by copyright. Copying for private or commercial purposes, in part or in 08
whole, is not
Note: with respect to the correctness of information in this document. Copyright by AUDI AG.
◆ Fitting locations of components => Pages 32 .

◆ If installing new heater controls (together with control unit -J214), the basic setting must be performed.
◆ With self-diagnosis started, the control functions of the heater remain operational and the positioning motors
can be activated.
◆ When the self-diagnosis is started, the control functions of the heater are not interrupted. However, they are
switched off if the following diagnostic functions are selected:
- Final control diagnosis
- Basic setting
◆ If thermotronic control unit -J214 continues to function after the ignition has been switched off, test for a
short circuit to positive in the wiring to -J214 (contact 1 on 16-pin connector).
=> Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
◆ On vehicles with auxiliary heater, the application of voltage at contact 1 on the 16-pin connector with the
ignition switched off activates the positioning motor and causes the air distribution to switch to the defrost
setting. Because the temperature flaps are actuated by Bowden cables, their positions cannot be changed.
The speed of the fresh air blower is also pre-determined by a series resistor.
◆ If new heater controls (including control unit -J214) are installed and the basic setting is not performed, the
heater may produce unwanted noises when operating because the flaps do not always reach their limit
stops.
2 01 - Self-diagnosis, Electrical check

Audi A6 1998 ➤
◆ The first 1000 vehicles produced in model year 1998 were fitted with heater controls incorporating a ther‐
motronic control unit -J214 and software version D42. The fault reader displays for these control units are
slightly different from those shown in this Workshop Manual:
- Sporadic faults are not erased automatically.
- For some faults, the display will show the message "Short circuit to earth" instead of "Short circuit".
- A fault which has occurred once may be indicated several times (as a sporadic fault and as a static fault).
1.4 - Test requirements for self-diagnosis

◆ All fuses according to current flow diagram OK.
◆ Battery voltage must be OK.
◆ The ignition must be switched on or the engine must be running.
1.5 - Safety notes
Note the following points if testers and measuring instruments have to be used during a road test:
Warning:
◆ Always secure the test devices to the rear seat and have a second person operate them from there.
◆ If test equipment were operated from the front passenger seat, the person sitting there could be injured if
the front passenger airbag were triggered in the event of an accident.
2 - Connecting vehicle diagnostic, measuring and information system VAS 5051

or fault reader V.A.G 1551 and selecting function
2.1 - Connecting vehicle diagnostic, measuring and information system VAS 5051 or fault
reader V.A.G 1551 and selecting function
- Switch off ignition.

- -> Remove the cover of the diagnostic connector.
1.3 - Technical data for self diagnosis 3

Audi A6 1998 ➤
- Connect up vehicle diagnostic, measurement and information system VAS 5051 with diagnostic cable VAS
5051/1.
Note:
◆ Alternatively, connect fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with diagnostic cable
V.A.G 1551/3.
◆ If testing and measuring equipment needs to be used during a test drive, observe the safety procedures =>
Page 3
◆ The following description only refers to the self-diagnosis procedure carried out using the fault reader V.A.G
1551.
◆ When using the vehicle diagnostic, measurement and information system VAS 5051, or the vehicle system
tester V.A.G 1552, follow the procedures described in the equipment's operating instructions.
-> Display readout:

font=symbol charset=fontspecific code=042 is displayed alternately.
V.A.G self diagnosis HELP
1- Rapid data transfer*
2- Flash code output*
Note:
◆ If nothing appears on the display of fault reader V.A.G 1551, check the wiring to diagnostic connector using
the current flow diagram.
◆ Depending on the program, it may be possible to print out additional operating instructions by pressing the
HELP key on the V.A.G 1551.
◆ The ⇒key is used to advance the program sequence.
◆ The PRINT key is used to switch on the printer (indicator lamp in the key lights up).
◆ The fault memory cannot be erased until it has been interrogated.
- Switch on ignition and/or start the engine.

- Press key -1- to select "Rapid data transfer" mode.
-> Display readout:

Rapid data transfer HELP
Enter address word XX
- Press keys -0- and -8- (08 is the address word for testing the vehicle's "heating/air conditioner electronics").
-> Display readout:

Rapid data transfer Q
08 AC/heating electronics
- Confirm entry with Q key.
-> Indicated on display after address word 08 has been entered:

Rapid data transfer
Tester transmits address word 08
-> After a short delay, the control unit identification will be displayed:
4B0 819 045 X by copyright.
Protected STG Heating A6 or commercial
Copying for private DXX purposes, in part or in whole, is not
◆ Control unit identification (depends on vehicle equipment and heater design, for allocation=> Parts
=> List).
◆ DXX indicates the software version installed in the thermotronic control unit -J214.

Audi A6 1998 ➤
Note:
◆ In the period from week 36 of 1998 to week 10 of 1999, production will be gradually switched from heater
design "1" to heater design "2". These designs have specific features that differ =>Page 55
◆ The control unit for thermotronic -J214 (incorporated in the heater controls) is different, therefore attention
must be paid to the correct assignment when renewing it.
=> Parts List
- For design "1" heaters, only heater controls (together with control unit for thermotronic -J214) with part
numbers up to index "F" may be installed.
- For design "2" heaters, only heater controls (together with control unit for thermotronic -J214) with parts
numbers up to index "H" may be installed.
◆ During self-diagnosis with thermotronic control unit -J214, an "X" is displayed with the part number instead
of an index. The index is located with the part number on the heater controls.
Summary of functions Page

01 - Interrogate control unit version 3
02 - Interrogate fault memory 6
03 - Final control diagnosis 9
04 - Basic setting 11
05 - Erase fault memory 13
06 - End output 13
08 - Read measured value block 14
Only the functions listed above can be used for the self-diagnosis of the air conditioner/heating system elec‐
tronics.
- Press ⇒key.
-> Indicated on display (function selection, e.g. 02 - Interrogate fault memory):

Select function XX
Note:
◆ Pressing the HELP key prints a summary of the possible functions.

◆ Pressing the ⇒ key returns the program of the V.A.G 1551 to its original setting.
◆ If one of the following fault messages appears on the display:
-
Control unit does not answer
-> Print the possible fault causes by pressing the HELP key.
-
K wire not switching to positive
-> Use current flow diagram to check wiring

of diagnostic plug.
->
Rapid data transfer Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
No signal from control unit permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
◆ data transfer
Rapid
Fault in communication build up
2.1 - Connecting vehicle diagnostic, measuring and information system VAS 5051 or fault
reader V.A.G 1551 and selecting function 5

Audi A6 1998 ➤
-> If this display appears at the beginning of the program or during the test, it indicates a system error which
is preventing data transfer between fault reader V.A.G 1551 and control unit -J214. Check wiring to diag‐
nostic connector using the current flow diagram.
- After eliminating the possible fault causes, enter address word 08 for "AC/heating electronics" again and
confirm with Q key.
-> Indicated on display after address word 08 has been entered:

The following display will then appear:
Rapid data transfer
Tester transmits address word 08
-> The control unit identification will be displayed:

4B0 819 045 X STG Heating A6 DXX
- Press ⇒key.
-> Indicated on display (function selection, e.g. 02 - Interrogate fault memory):

Select function XX
3 - Interrogating fault memory

3.1 - Interrogating fault memory
- Connect fault reader V.A.G 1551,
enter address word 08 "AC/heating electronics" and advance the program until "Select function XX" appears
on display (=>Page 3 onwards).
- Switch on printer by pressing PRINT key (indicator lamp in key lights up).
-> Display readout (function selection):

Select function XX
- Press keys -0- and -2- (02 selects the "Interrogate fault memory" function.)
-> Display readout:

02 - Interrogate fault memory
-> The number of stored faults or "No faults detected" appears on the display.
X faults detected
No fault detected
- Press the ⇒key.
The stored faults are displayed and printed out

Protected by one after
copyright. Copyinganother.
for private or commercial purposes, in part or in whole, is not
- When the last fault has been displayed and toprinted
with respect out rectify
the correctness faults
of information indocument.
in this line with fault by
Copyright table.
AUDI AG.
(=>Page 7 ).
As with "no fault detected", the program returns to its starting position when the ⇒key is pressed.

Audi A6 1998 ➤

Select function XX
- End output (function 06) =>Page 13 .

- Switch off ignition and disconnect diagnostic connector.
Note:
◆ If a fault was detected:
- 1. Rectify the fault.
- 2. Interrogate fault memory (function 02).
- 3. Erase fault memory (function 05).
- 4. Perform basic setting (function 04).
- 5. Interrogate fault memory (function 02).

- 6.End output (function 06).
◆ If no faults have been detected even though problems have been reported with the heater:
- 1. Read measured value block (function 08) =>Page 14 .
- 2. Perform final control diagnosis (function 03)=>Page 9 .
- 3. Perform basic setting (function 04)
=>Page 11
- 4. Check Bowden cables to the temperature flaps
- 5. Perform electrical test =>Page 18
◆ If the buttons and rotary controls on the heater do not light up when the vehicle lights are switched on, test
the voltage supply through terminals 58s and 58d (switch illumination)=>Page 18 (Electrical test).
4 - Fault table
4.1 - Fault table
Note:
◆ Listed below, by fault code number, are all the faults which can be detected by the thermotronic control unit
-J214 (fitted in heater controls) and displayed on V.A.G 1551.
◆ Faults are displayed as being "sporadic faults" if they only occur from time to time or if the fault memory has
not been erased following fault rectification (the content of the fault memory is retained until it is erased -
"non-volatile memory". Sporadic faults are erased from the fault memory if they do not occur again after the
ignition has been switched on and off 15 times.
◆ In "Rapid data transfer" mode, the fault code only appears on the printout.
◆ An indication of the type of fault may also appear in the fault table. (One of the displays marked with * appears
together with the component concerned or the "info"-display).
◆ Once repairs have been completed, the fault memory must always to be interrogated again with fault reader
V.A.G 1551 and erased.
◆ Before renewing components, always check the relevant positive and earth connections (terminals 15, 75,
30 and 31) as well as all connectors (between control unit -J214 and the component indicated as being
faulty) according to the current flow diagram.
◆ With all sporadic faults, it is particularly important to check the connectors for possible loose contacts.
◆ If a heating system component is renewed, the basic setting (function 04) should always be performed. The
fault memory must then be interrogated and any faults indicated must be rectified and erased from the
memory (functions 02 and 05).
◆ Use test box V.A.G 1598/12 to test the electrical connections of the control unit -J214 in accordance with
the current flow diagram.
◆ If thermotronic control unit -J214 continues to function after
permitted the
unless ignition
authorised hasAG.
by AUDI been switched
AUDI AG off, test
does not guarantee for a any liability
or accept
short circuit to positive in the wiring to -J214 (contactwith
1 on 16-pin
respect to the connector), using inthe
correctness of information thiscurrent
document. flow diagram.
Copyright by AUDI AG.
◆ If a fault is detected on the potentiometer in one of the air distribution positioning motors, the air distribution
can be changed by actuating the rotary control on the heater controls (backup mode).
◆ If no fault is detected despite complaints about the air conditioner/heating electronics, the functions "Final
control diagnosis 03" and "Read measured block 08" should be performed.
◆ The control unit -J214 will only record a sporadic fault as a permanent fault if it is still present after a certain
period of time, or if several unsuccessful attempts have been made to rectify it (for example, if the position
of the rotary control for air distribution has been changed 5 times but the positioning motor has not moved).
3.1 - Interrogating fault memory 7

Audi A6 1998 ➤
If a sporadic fault no longer occurs after a certain period of time (e.g. after the ignition has been switched
on and off 15 times) it is automatically erased from the fault memory.
◆ If the message "short circuit" is displayed, the short circuit could also be in the component (between an input
and an output, e.g. in the commutator for the positioning motor).
◆ If the fault memory indicates that several of the positioning motors are defective but no faults can be found,
test for short circuits in the wiring between the individual positioning motors; also test for short circuits to
earth.
◆ The first 1000 vehicles produced in model year 1998 were fitted with heater controls incorporating a ther‐
motronic control unit -J214 and software version D42. The fault reader displays for these control units are
slightly different from those shown in this Workshop Manual:
- Sporadic faults are not erased automatically.
- For some faults, the display will show the message "Short circuit to earth" instead of "Short circuit".
- A fault which has occurred once may be indicated several times (as a sporadic fault and as a static fault).
Output on printer of V.A.G 1551 Possible fault cause Fault elimination

00000 If "No fault detected" appears after performing repairs, the self-diagnosis
No fault detected is completed.
00601 - Short circuit, open circuit or error in - Use current flow diagram to locate
Potentiometer -G112 in the position‐ connector wiring between -G112 and rectify short circuit, open circuit
ing motor -V70 (for central flap) and -J214. or error in connector wiring.
*Short to earth/SP Central flap or footwell flap stiff. Check freedom of movement of
*Open/short circuit to Potentiometer -G112 in -V70 defec‐ central flap and footwell flap2)
positive/SP tive Renew positioning motor -V70
*Adaption limit
exceeded 1)
Defrost flap positioning motor connector wiring between -V107 and rectify short circuit, open circuit
-V107 and or error in connector wiring.
*Blocked or without voltage -J214 Check the freedom of movement of
/SP Defrost flap stiff. the defrost flap
* Short circuit/SP Positioning motor -V107 defective Check positioning motor -V107 (=>
* Adaption has not been carried out New heater controls fitted but no ba‐ Final control diagnosis, Page
sic setting was performed. 9 ).
Perform basic setting of control unit
-J214
1) This fault is only detected during basic setting.
2) Both limit stops must be reached.

Potentiometer -G135 in positioning connector wiring between -G135 and rectify short circuit, open circuit
motor -V107 (for defrost flap) and -J214. or error in connector wiring.
*Short to earth/SP Defrost flap stiff. Check freedom of movement of de‐
*Open/short circuit to Potentiometer -G135 in -V107 de‐ frost flap2)
positive/SP fective Renew positioning motor -V107
*Adaption limit
exceeded 1)

Audi A6 1998 ➤

01272 4123 - Short circuit, open circuit or error in - Use current flow diagram to locate
Positioning motor for central flap - connector wiring between -V70 and and rectify short circuit, open circuit
V70 -J214 or error in connector wiring.
*Blocked or without voltage Central flap or footwell flap stiff. Check freedom of movement of
/SP Positioning motor -V70 defective central flap and footwell flap
* Short circuit/SP New heater controls fitted but no ba‐ Check positioning motor -V70 (=>
* Adaption has not been carried out sic setting was performed. Final control diagnosis, Page
9 ).
Perform basic setting of control unit
-J214
1) This fault is only detected during basic setting.
2) Both limit stops must be reached.

01596 - Short circuit or open circuit in wir‐ - Use current flow diagram to locate
Fresh/recirculated air positioning ing between -V154 and and rectify short circuit or open cir‐
motor -V154 Protected-J214 cuitin part or in whole, is not
by copyright. Copying for private or commercial purposes,
*Short to earth/SP Fresh/recirculated
permitted unless authorised by AUDIairAG. flap
AUDI stiff Checkor the
AG does not guarantee accept freedom
any liability of movement of
* Short circuit/SP Positioning
with respect motorof-V154
to the correctness defective
information the
in this document. fresh/recirculated
Copyright by AUDI AG. air flap
Check positioning motor -V154 (=>
Final control diagnosis, Page
9 ).
Note:
◆ Positioning motor -V154 has no potentiometer to identify its position. The motor is activated by the control
unit for a pre-determined period (about 10 seconds). If it moves in the opposite direction, the polarity (positive
and negative) of the outputs in the control unit is reversed.
◆ If there is a short to positive or an open circuit in the wiring between control unit -J214 and the positioning
motor -V154, this might not be identified as a fault.
◆ If there is a short to earth in the wiring between control unit -J214 and one of the positioning motors, it is
possible that another positioning motor will be identified as defective.
5 - Final control diagnosis

5.1 - Final control diagnosis
Note:
◆ Fitting locations of the actuated components =>Page 32 .

◆ The final control diagnosis can be performed more than once if necessary.
◆ During the final control diagnosis, the control function is switched off (the setting of the rotary control for air
distribution will not change the positions of the positioning motors and the system will operate in fresh-air
mode).
Starting the final control diagnosis.
- Start engine.
- Set air distribution to dash panel vents.
- Open the dash panel vents.
- Set rotary control for fresh air blower speed to "2".

on display =>Page 3 .
4.1 - Fault table 9

Audi A6 1998 ➤
- Interrogate fault memory => Page 6 .

Select function XX
- Press keys -0- and -3- (03 selects the "Final control diagnosis" function).
-> Display readout:

03 -Final control diagnosis
-> Display readout:

Final control diagnosis
Defrost flap positioning motor-V107
- The ⇒key can be used to advance to the next component.
Note:
◆ To make it easier to check the air distribution, the activated positioning motor remains in each of the pre-
set positions for about 6 seconds.
◆ Final control diagnosis can be stopped by pressing key C.

◆ When final control diagnosis has been completed, interrogate the fault memory => Page 6 .
-> Display readout:

Function is unknown or
cannot be carried out at the moment
- This display indicates completion of the final control diagnosis.

- Press ⇒key.
Indicated on display Specified function Fault elimination

Defrost flap positioning motor - Positioning motor -V107 moves from - Test wiring between -V107 and
-V107 stop to stop (defrost flap opens and -J214 for open circuit or wrong con‐
closes) 1). nection, using current flow diagram.
Volume of air from windscreen vents Check the freedom of movement of
changes the defrost flap
Electrical test, Page 18 ).
Renew control unit -J214

Audi A6 1998 ➤

Central flap positioning motor - Positioning motor -V70 moves from - Test wiring between -V70 and
-V70 stop to stop2). -J214 for open circuit or wrong con‐
Air distribution switches between foot‐ nection, using current flow diagram.
well and dash panel vents Check freedom of movement of cen‐
tral flap and footwell flap
Electrical test, Page 18 ).
1) The fresh/recirculated air flap is set to the "fresh air" position and the central flap and footwell flap are
closed.
2) The fresh/recirculated air flap is set to the "fresh air" position and the defrost flap is closed.
The motor moves to the following positions:
- Central flap and footwell flap closed.
- Central flap open and footwell flap closed.
- Footwell flap open and central flap closed, etc.

Fresh/recirculated air flap position‐ - Positioning motor -V154 moves - Test wiring between -V154 and
ing motor -V154 from stop to stop (fresh air and recir‐ -J214 for open circuit, using current
culated air modes) 1). flow diagram.
Heater switches between "fresh air" Check the freedom of movement of
and "recirculated air" modes. the fresh/recirculated air flap
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Electrical test, Page 18 ).
1) The central flap and the footwell flap are closed, the defrost flap is open. The operation of the positioning
motor can be observed if the dust and pollen filter is removed.
6 - Basic setting
6.1 - Basic setting
Requirements
◆ Engine running
◆ All electrical equipment with high power consumption must be switched off (e.g. lights, rear window heating,
etc.).

on display =>Page 3 onwards
- Interrogate fault memory =>Page 6 and rectify any faults that may be indicated.
- Erase fault memory =>Page 13 .

Select function XX
- Press keys -0- and -4- (04 selects the "Basic setting" function).
-> Display readout:
5.1 - Final control diagnosis 11

Audi A6 1998 ➤

04 - Start basic setting
-> Display readout:

Start basic setting HELP
Enter display number XXX
- Enter display group number 01 or 001 (depending on the software version installed in the fault reader).
Note:
◆ The following positioning motors are now actuated one after the other and their limit stop positions are stored
in control unit -J214 (resistance of the potentiometers fitted in the positioning motors):
- Positioning motor for central flap -V70
- Defrost flap positioning motor -V107
◆ If new heater controls (including control unit -J214) are installed and the basic setting is not performed, the
heater may produce unwanted noises when operating because the flaps do not always reach their limit
stops.
-> Display readout:

Basic setting 1
XXX XXX
Note:
It is possible to track the movement of the positioning motors on the display (feedback values change).
-> Display readout:
Basic setting 1
0 0
When 0 appears on the display, basic setting has been completed.
- Press ⇒key.

Select function XX
- Press keys -0- and -2-. (02 selects the "Interrogate fault memory" function.)
-> Display readout: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Rapid data transfer Q with respect to the correctness of information in this document. Copyright by AUDI AG.
02 - Interrogate fault memory
-> The number of stored faults or "No faults detected" appears on the display.
X faults detected
- Press the ⇒key.
The stored faults are displayed and printed out one after another.
- When the last fault has been displayed and printed out rectify faults in line with fault table.
(=> Page 7 ).
- Press ⇒key.

Audi A6 1998 ➤

Select function XX
7 - Erasing fault memory, ending output

7.1 - Erasing fault memory, ending output
Requirement
◆ The fault memory has been interrogated.
Erasing fault memory
- Press ⇒key.

Select function XX
- Press keys -0- and -5- (05 selects the "Erase fault memory" function.)
-> Display readout:

05 Erase fault memory
-> Display readout:

Rapid data transfer
Fault memory is erased!
- Press ⇒key.
-> Display readout:

Select function XX
Note:
◆
Warning:
Fault memory was not interrogated
-> If the text shown opposite appears on the display, the test procedure has not been performed correctly.
◆ Follow the test sequence exactly:
- Interrogate fault memory:
- Rectify any faults.
- Erase fault memory.
◆ If, for example, the ignition was switched off between "Interrogate fault memory" and "Erase fault memory",
the fault memory will not have been erased (interrogate the fault memory again).
Ending output
Note:
The fault memory has been interrogated and erased and the basic setting has been performed.
-> Display readout:

Rapid data transfer HELP by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted unless authorised
Select functionwith
XXrespect to the correctness of information in this document. Copyright by AUDI AG.
6.1 - Basic setting 13

Audi A6 1998 ➤
- Press keys -0- and - 6- (06 selects the "End output" function.)
-> Display readout:

06 End output
-> Display readout:

Enter address word XX
- Switch off ignition and disconnect diagnostic connector.
8 - Reading measured value block

8.1 - Reading measured value block
Note:
◆ There are 4 measured value blocks with 4 measured values each.

◆ The heater control function remains switched on during self-diagnosis (function "Read measured block val‐
ue") and the current measured values are displayed.
◆ Display Groups 1 and 2 show the current actual or specified value or the value learnt and stored during the
last basic setting for the limit stops of the individual positioning motors.
◆ The position of the positioning motors, and therefore of the flaps, can be changed during the self-diagnosis
using the rotary control for air distribution, and the current actual and specified values can be read off the
fault reader display.
◆ If the printer is switched on, the current display will be printed out on the record slip.
Starting "Read measured value block" function
- Start engine.
- Set rotary control for fresh air blower speed to "2".
- Connect fault reader V.A.G 1551, enter address word 08 "AC/heating electronics" and advance the program
until "Select function XX" appears on display => Page 3 onwards.
-> Display readout (function
permitted selection):
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the
Rapid data transfer correctness of information in this document. Copyright by AUDI AG.
HELP
Select function XX
- Press keys -0- and -8-. (08 selects the "Read measured value block" function.)
-> Display readout:

08 - Read measured value block
-> Display readout:

Read measured value block
Enter display group number XXX
- Enter display group number (overview =>Page 15 ).

-> Display readout:

Read measured value block X
1 2 3 4

Audi A6 1998 ➤
Select another display group:
- Press key C.
-> Display readout:

Read measured value block
Enter display group number XXX
- Enter display group number.
Note:
◆ Pressing key "3" or the "↑"key advances the program to the next display group; pressing "1" or the "↓" key
moves the program back by one display group.
◆ If all the display zones show the specified values:
- Press ⇒key
-> Display readout:

Select function XX
Overview of the display group numbers to be selected
Display Group by No.

AUDIDisplay zone Designation Details on Page
permitted unless authorised AG. AUDI AG does not guarantee or accept any liability
01 1-4 Defrost flap positioning motor-V107
15
02 1-4 Positioning motor for central flap -V70 16
03 1 Output to rear window heating 16
2 Output to positioning motor for fresh/recirculated air flap
3 Output for "Econ" mode (only relevant on diesel models)
4 Position of rotary control for air distribution
04 1 Voltage at control unit -J214 (in volts) 17
2 Unallocated
3 Unallocated
4 Unallocated
Display Group 01 (defrost flap positioning motor -V107)
Display zone Display

1 Actual feedback value of potentiometer -G135 (in positioning motor -V107)
Display value greater than 5 and less than 250
Maximum permissible deviation: 3 units greater or lesser than the specified feedback value (only
in the range greater than 50 but less than 200)
2 Specified feedback value for potentiometer -G135 (calculated by control unit -J214)
Display range: 5 to 250
3 Value for -G135 that was calculated during the basic setting and stored in control unit -J214 with
the positioning motor at the upper limit stop (defrost flap closed)
4 Value for -G135 that was calculated during the basic setting and stored in control unit -J214 with
the positioning motor at the lower limit stop (defrost flap open, air coming from windscreen de‐
froster vents)
8.1 - Reading measured value block 15

Audi A6 1998 ➤
Note:
◆ If the display values in display zones 3 or 4 are outside the permitted range =>Fault table, Page 7 .
◆ If the feedback value in display zone 1 is less than 5 (short circuit) or greater than 250 (open circuit), perform
electrical test =>Page 18
◆ The actual feedback value (between 5 and 50 and between 200 and 250) is specified as the permitted
tolerance range for the positioning motor stop or the flap in the thermotronic control unit -J214.
Display Group 02 (central flap positioning motor -V107)

1 Actual feedback value for potentiometer -G112 (in the positioning motor -V70)
Maximum permissible deviation: 3 units greater or less than the specified feedback value (only
in the range greater than 50 but less than 200)
2 Specified feedback value for potentiometer -G112 (calculated by control unit -J214)
Display range: 5 to 250
3 Value forProtected
-G112bythat wasCopying
copyright. calculated
for privateduring the purposes,
or commercial basic setting and
in part or in stored
whole, is not in control unit -J214 with
the positioning motor at the upper limit stop (central flap closed, air
directed to the defrost flap
and the footwell flap)
4 Value for -G112 that was calculated during the basic setting and stored in control unit -J214
with the positioning motor at the lower limit stop (central flap directs air to the dash panel vents).
Note:
◆ If the display values in display zones 3 or 4 are outside the permitted range =>Fault table, Page 7 .
◆ If the feedback value in display zone 1 is less than 5 (short circuit) or greater than 250 (open circuit) perform
electrical test =>Page 18
◆ The actual feedback value (between 5 and 50 and between 200 and 250) is specified as the permitted
tolerance range for the positioning motor stop or the flap in the control unit -J214.
Display Group 03 (control unit outputs and position of rotary control for air distribution)

1 Activation of rear window heating -Z1
0 = rear window heating off
1 = rear window heating on (indicator lamp in the button for rear window heater lights up)
2 Activation of fresh/recirculated air flap positioning motor -V154
0 = positioning motor in "fresh air" position
1 = positioning motor in "recirculated air" position (indicator lamp in button for recirculated air
mode lights up)
3 Activation of additional heater (vehicles with diesel engines only)
Input is switched to earth (additional heater function required)
Input is open ("Econ" mode - additional heater function is not required, indicator lamp in "Econ"
button lights up)
4 Position of rotary control for air distribution
Display value between 0 and 255 (depending on position of rotary control)
Display value changes continuously as rotary control is turned
Notes on display zone 1:
◆ The on-time for the rear window heating is limited by control unit -J214 to about 15 minutes.
◆ The rear window heating will only be activated if the voltage at terminal 15 is greater than 10.8 V. If the
voltage drops below 10.8 V, the rear window heating is switched off.
◆ The rear window heating is automatically switched off when the ignition is switched off.

Audi A6 1998 ➤
◆ The recirculated air function will not operate when the system is in defrost mode. If the rotary control for air
distribution is switched to the defrost mode position, control unit -J214 will move positioning motor -V154 to
the fresh air mode position.
◆ The control unit registers defrost mode when the air distribution rotary control is between 330o and 30o(11
o'clock and 1 o'clock positions).
◆ If the rotary control for air distribution is turned beyond the "defrost mode" range without stopping, the re‐
circulated air function is not switched off.
◆ If the ignition is switched off and then on again, the "recirculated air" function is cancelled and positioning
motor -V154 is moved to the "fresh air mode" position.
◆ The additional heater is only intended for vehicles with diesel engines and for specific markets. The display
zone can be ignored for models with petrol engines.
◆ The following system is fitted:
- Electric additional heater (air is heated as soon as it leaves the heat exchanger
in the heater).
◆ If an auxiliary heater (optional equipment) is fitted, this can be switched on independently of the electric
additional heater, using the pre-selector/timer.
=> Auxiliary heater
◆ The engine control unit will switch on the additional heater if the following conditions exist:
- Control unit -J214 has switched the input (16-pin connector, contact 12) to earth ("Econ" mode
not selected),
- Ambient temperature switch -F38 is closed (only fitted on models with 4-cylinder diesel engines).
- Engine speed is greater than 600 rpm.
- Coolant temperature is less than 70 oC (or less than 80 oC at very low ambient temperatures).
- The load on alternator -C is less than 60%.
=> Diesel direct injection and glow plug system
◆ The ambient temperature switch -F38 (only fitted on models with 4-cylinder diesel engines) is closed at
ambient temperatures of less than +6 oC. The additional heater is only activated when the switch is closed.
◆ If the additional heater function is not required and "Econ" mode is selected, this setting will remain even
after the ignition is switched off and on again.
Display Group 04 permitted
(voltage at authorised
unless control byunit
AUDI-J214)
AG. AUDI AG does not guarantee or accept any liability

1 Voltage at terminal 15 (contact 8 on 16-pin connector)
If the display value is less than 12 V while the engine is running, test wiring to control unit -J214
(positive and earth), using the current flow diagram.
2 Display field not used (ignore display).
8.1 - Reading measured value block 17

Audi A6 1998 ➤
9 - Electrical test of heater controls

9.1 - Electrical test of heater controls
Measuring and test equipment required:

- -> Test box V.A.G 1598 and associated adapter cable V.A.G 1598/12
- Handheld multimeter V.A.G 1526
- Adapter set V.A.G 1594
- Diode test lamp V.A.G 1527
Test requirements:
All fuses according to current flow diagram OK.
Connecting test box V.A.G 1598 between connector and control unit -J214
- Remove radio.
=> Electrical system

- -> Release catch -A- on connector and detach connector -B- from heater controls.
Note:

Audi A6 1998 ➤
If the catch on the connector for the heater controls cannot be released, remove the heater controls together
with the control unit -J214 (=>Page 37 ).
- -> Connect adapter lead V.A.G 1598/12 to connector and control unit -J214.
Note:
◆ The socket assignment on adapter cable V.A.G 1598/12 is identical to the pin assignment on control unit -
J214
◆ Note that there are some test steps in which control unit -J214 must not be connected to the test box.
Summary of electrical tests to be performed on control unit -J214
Test step Component tested Page

1 Voltage supply, earth connection and illumination for heater controls 19
2 Outputs and inputs of control unit -J214 20
Activation of fresh/recirculated air flap positioning motor -V154
3 Heating system positioning motors and associated potentiometers 21
Central flap positioning motor -V70 and associated potentiometer -G112
Defrost flap positioning motor -V107 and associated potentiometer -G135
Fresh/recirculated air flap positioning motor -V154
4 Outputs/inputs which are only present with certain vehicle equipment combinations: 22
Output
Protected forCopying
by copyright. additional heater
for private (vehicles
or commercial with
purposes, diesel
in part engines
or in whole, is not only)
Input
permitted unlessfor auxiliary
authorised by AUDIheater
AG. AUDI AG does not guarantee or accept any liability
Test step 1 (voltage supply, earth connection and illumination for heater controls)
Select measuring range on the hand-held multimeter V.A.G 1526

Voltage measurement (20 V =)
- Adapter cable V.A.G 1598/12 connected
- All connectors fitted to heater controls
Test step V.A.G 1598 Test on ▪ Test conditions Specification Remedies if speci‐
socket - Additional work fied values not at‐
tained
1.1 8 Terminal 15 and ▪ Ignition on - Approx. battery - Use current flow di‐
and earth connection on voltage agram to repair pow‐
16 -J214 er supply and/or
earth connection
1.2 11 Terminal 58s on - ▪ Ignition on - 0 to 12 V - Use current flow di‐
and J214 ▪ Side lights on agram to locate and
16 rectify open circuit or
short circuit

Test step V.A.G 1598 Test on ▪ Test conditions Specification Remedies if specified
socket - Additional work values not attained
1.3 11 Terminal 58s on -J214 ▪ Ignition on. - Approx. 0 V. - Use the current flow
and ▪ Side lights off diagram to locate and
16 rectify short to positive
Note:
◆ The voltage at terminal 58s is governed by the setting of the instrument illumination control.
9.1 - Electrical test of heater controls 19

Audi A6 1998 ➤
◆ The voltage at terminal 58s determines the brightness of the illumination for the heater controls (rotary
control).

1.4 5 Terminal 58d on -J214 ▪ Ignition on. - 0 to 12 V - Use current flow dia‐
and ▪ Side lights on gram to locate and rec‐
16 tify open circuit or short
Protected by copyright. Copying for private or commercial purposes, in part circuit
or in whole, is not
1.5 5 Terminal 58d
with onto-J214
respect ▪ Ignition
the correctness on. in this-document.
of information 0 to 12Copyright
V - by UseAUDIcurrent
AG. flow dia‐
and ▪ Side lights off gram to locate and rec‐
16 tify open circuit or short
circuit
Note:
◆ The voltage at terminal 58d is generated as a square-wave signal by the dash panel insert. The brightness
of the illumination for the heater control buttons is determined by the period of activation. The tester will
show the mean value.
◆ The actuation period at terminal 58d is governed by the setting of the illumination control and the brightness
level determined by the photosensor in the dash panel insert.
Test step 2 (activation of fresh/recirculated air flap positioning motor -V154)
Voltage tester V.A.G 1527,

- Rotary control for air distribution in "air to footwell" position
tained
2.1 1 Activation of -V154 ▪ Ignition on.
and ▪ Indicator lamp in
2 recirculated air but‐
ton not lit
- Press recirculated - Indicator lamp in - Renew heater con‐
air button button lights up trols (together with
LED on voltage test‐ control unit -J214)
er lights up (for 3 - 10 Locate and rectify
seconds). the short circuit using
Positioning motor the current flow dia‐
should move to "re‐ gram
circulated air" posi‐ Check positioning
tion motor -V154 =>Test
step 3

Audi A6 1998 ➤

- Rotary control for air distribution in "air to footwell" position
tained
2.2 1 Activation of -V154 ▪ Ignition on.
and ▪ Indicator lamp in
2 recirculated air but‐
ton lit
- Move rotary control - Indicator lamp in - Renew heater con‐
for air distribution to recirculated air but‐ trols (together with
"air to windscreen" ton should go out control unit -J214)
position LED on voltage test‐ Locate and rectify
er lights up (for 3 - the short circuit us‐
10 seconds). ing the current flow
Positioning motor diagram
should move to Check positioning
"fresh air" position motor -V154 =>Test
step 3
Test step 3 (heating system positioning motors and associated potentiometers

Resistance measurement (20 kω)
- 16-pin connector not fitted to heater controls
Test step V.A.G 1598
permitted Test
unless authorised on AG. AUDI ▪AGTest
by AUDI conditions
does not guarantee or acceptSpecification
any liability Remedies if speci‐
socket - Additional work
fied values not at‐
tained
3.1 15 Potentiometer (in - Greater than 0.1 - Use current flow di‐
and the positioning mo‐ kωand less than agram to locate and
13/ tor) 5.7kω (depending on rectify open circuit,
14 -G112 (-V70) the setting of the po‐ contact resistance or
-G135 (-V107) sitioning motor) short circuit
Renew positioning
motor
3.2 6 Potentiometer (in - Greater than 0.1 - Use current flow di‐
and the positioning mo‐ kωand less than agram to locate and
13/ tor) 5.7kω(depending on rectify open circuit,
14 -G112 (-V70) the setting of the po‐ contact resistance or
-G135 (-V107) sitioning motor) short circuit
Renew positioning
motor
Note:
◆ The resistance of potentiometers in the positioning motors (specified value: 3.6 kωto 5.7 kω between contact
1 and 3) can only be measured directly on the positioning motor (parallel connection).
◆ The resistance of the potentiometers in the positioning motors (between contacts 1 and 2 and contacts 3
and 2) is governed by the setting of the positioning motor , it must only be measured with the positioning
motorfitted. The maximum specified value will not be obtained in test steps 3.1 and 3.2. (To obtain the
maximum specified value, the connector on the other positioning motor would have to be detached; the
motors are connected in parallel).
◆ If control unit -J214 detects the fault "potentiometer short to earth" or "open circuit/short to positive", check
both potentiometers (in the positioning motors) and the associated wiring.
◆ If the fault memory indicates that both of the positioning motors are defective but no faults are found in test
step 3, test for short circuits in the wiring between the individual positioning motors.

Audi A6 1998 ➤
◆ On vehicles with right-hand drive, contacts 1 and 3 and 4 and 6 on the positioning motor are reversed (check
Part No. and current flow diagram).
=> Parts List

Resistance measurement (200 ω)
3.3 3 Positioning motor for - 20 ωto 100ω. - Use current flow dia‐
and central flap -V70 gram to locate and rec‐
4 tify open circuit, con‐
tact resistance or short
circuit
3.4 2 authorised
permitted unless Defrost
by AUDIflap position‐
AG. AUDI - 20 ωto 100ω. - Renew positioning
AG does not guarantee or accept any liability
and ing motor -V107
with respect to the correctness of information in this document. Copyright by AUDI AG. motor
3
3.5 1 Fresh/recirculated air - 20 ωto 100ω.
and flap positioning motor -
2 V154
Note:
◆ The control unit -J214 activates the positioning motors one at a time. It is therefore possible for two posi‐
tioning motors to be activated via the same output.
◆ If the fault memory indicates that two positioning motors are defective but no faults can be found, test for
short circuits in the wiring between the individual positioning motors; also test for short circuits to earth.
◆ The direction of operation of the positioning motors is determined by the polarity (positive and negative) of
the outputs on control unit -J214.
Test step 4 Outputs/inputs which are only present with certain vehicle equipment combinations (additional
heater
on diesel models, auxiliary heater)

Test step V.A.G 1598 Test on ▪ Test conditions Specification
Remedies if speci‐
tained
4.1 8 Signal to engine ▪ Ignition on. LED in voltage test‐ - Trace and elimi‐
and control unit to ▪ Indicator lamp in er should not light nate short to earth in
12 switch on additional "Econ" button lit. up. wiring between the
heater (diesel mod‐ If indicator lamp engine control unit/
els only) does not light up, ambient tempera‐
press "Econ" button ture switch -F38 and
-J214, using current
flow diagram
Test engine control
unit.
=> Diesel direct in‐
jection and glow
plug system

Audi A6 1998 ➤
Note:
◆ In "Econ" mode, the output for activation of the additional heater is not switched (output in control unit -J214
open).
◆ When "Econ" mode is not selected, the engine control unit receives an "earth signal" telling it that the ad‐
ditional heater can be activated if required.

tained
4.2 8 Signal to engine ▪ Ignition on. - LED in voltage - Trace and elimi‐
and control unit to Press "Econ" button tester should light nate short to posi‐
12 switch on additional ▪ Indicator lamp in up. tive in wiring be‐
heater (diesel mod‐ "Econ" button is off. tween the engine
els only) control unit/ambient
temperature switch
-F38 and -J214, us‐
ing current flow dia‐
gram
Test engine control
unit.
jection and glow
plug system
Note:
◆ On vehicles with 6-cylinder diesel engine, the engine control unit receives a signal via this outputtellling
it ,that the additional heater can be activated if required.
◆ On vehicles with 4-cylinder diesel engines, the engine control unit receives a signal via the ambient tem‐
perature switch -F38 (closed at temperatures lower than + 6 oC) tellingit ,that the additional heater can be
activated if required.

Current measurement (20 A =)
tained
4.3 12 Signal to engine ▪ Engine running - less than 5 mA - Use current flow
and control unit to ▪ Fault reader When the earth con‐ diagram to locate
16 switch on additional V.A.G 1551 con‐ nection is made, the and rectify open cir‐
heater (6-cylinder nected relevant display in cuit or short to posi‐
diesel models only) ▪ Measured value the measured value tive in the wiring be‐
block for additional block of the engine tween the engine
heater selected control unit should control unit and -
=> Diesel
Protected direct
by copyright. in‐ forchange
Copying from "0"purposes,
private or commercial to J214.in part or in whole, is not
jection
permitted and
unless glow by AUDI
authorised "1"AG. AUDI AG does not guaranteeTest engine
or accept any control
liability
plug
with system
respect unit. by AUDI AG.
to the correctness of information in this document. Copyright
jection and glow
plug system
Note:
◆ On vehicles with 4-cylinder diesel engine, this signal is sent via the ambient temperature switch -F38 which
opens at a temperature of +6 oC. Therefore the test cannot be carried out

Audi A6 1998 ➤
◆ Vehicles with 4-cylinder diesel engines are fitted with ambient temperature switch -F38 because the engine
control unit is unable to process the ambient temperature signal from the dash panel insert.

- No connectors fitted to heater controls
Test step V.A.G 1598 Test on ▪ Test conditions Specification
Remedies if speci‐
tained
4.4 9 Signal from auxili‐ ▪ Ignition off. - Approx. 0 V - Use the current
and ary heater (only on ▪ Heater switch in Shortly after auxiliary flow diagram to lo‐
16 vehicles with auxil‐ "Heater" position heater is switched cate and rectify
iary heater) (auxiliary ventilation on, voltage should short to positive
mode) change to approx. Use current flow di‐
Switch on the auxili‐ voltage of electrical agram to locate and
ary heater via pre- system rectify open circuit
selector/timer (auxil‐ or short to earth in
iary ventilation the wiring between
mode) auxiliary heater and
-J214.
Check operation of
auxiliary heater
Note:
◆ If voltage is applied to this input on control unit -J214 while the ignition is switched off, control unit -J214 will
close the footwell flap and the central flap and open the defrost flap (air directed onto windscreen)
◆ In auxiliary heater mode, the output of the auxiliary heater is only activated when the temperature of the
coolant in the auxiliary heater exceeds a certain level.
=> Auxiliary heater

◆ When the auxiliary heater is switched on, fresh air blower -V2 is operated at a pre-defined speed via a series
resistor -N6.
10 - Electrical test of rear window heating

10.1 - Electrical test of rear window heating
Measuring and test equipment required:

- Multimeter V.A.G 1715 (with current probe)
- Adapter set V.A.G 1594
Test requirements:

Audi A6 1998 ➤
All fuses according to current flow diagram OK.

- Remove radio.
- -> Release catches -B- on connector and detach connector from heater controls.
Note:
If the catch on the connector for the heater controls cannot be released, remove the heater controls together
with the control unit -J214 (=> Page 37 ).
- Switch on ignition.
- Measure voltage between contacts 1 and 2 (Specification: approx. battery voltage
- Fit connector -B- to heater controls.
- -> Pass wire -A- (from connector -B-) through the current probe of V.A.G 1715
Note:
All connectors are fitted to the heater controls
- Select the function "Current measurement via current probe" on V.A.G 1715.
- Start engine.
- Switch on rear window heating at the heater controls (indicator lamp in button lights up).
Display on the V.A.G 1715 changes from approx. 0 A to less than 25 A
After about 15 minutes, the display changes from less than 25 A to approx. 0 A (indicator lamp in button goes
out) Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note:
◆ The current probe may be influenced by stray current which could cause the display to show a low current
reading when the rear window heating is switched off.
◆ The on-time for the rear window heating is limited by control unit -J214 to about 15 minutes.
11 - Electrical test of additional heater

11.1 - Electrical test of additional heater
Note:
◆ The electric additional heater is only fitted on diesel models.
10.1 - Electrical test of rear window heating 25

Audi A6 1998 ➤
◆ Testing activation of heating elements
◆ The electrical additional heater is activated by the control unit for the diesel direct injection and glow plug
system when the following conditions occur at the same time:
- The load on alternator -C is less than 60%.
- Engine speed greater than 600 rpm
- Coolant temperature is less than 70 oC (or less than 80 oC at very low ambient temperatures).
- Control unit -J214 in the heater controls has switched the input to earth ("Econ" button not pressed,
indicator lamp in the "Econ" button does not light up).
- Ambient temperature switch -F38 is closed (only fitted on models with 4-cylinder engines).
- Other activation conditions
- To test the heating elements of the additional heater, first remove the driver's storage compartment
=> General body repairs, Interior; Repair Group 68
- -> Unplug connectors -A-, -B- and -C- from the heater and test each heating element (-D-, -E- and -F-)
separately for short circuits. The value obtained between contacts 1 and 2 should be between 0.2 and 5
ω).depending on the temperature.
- Test the heating elements -D-, -E- and -F- for short circuits to each other. Specification: ∞ω).
Note:
◆ Additional heater element -Z35 consists of three PTC (positive temperature coefficient) resistors which are
individually wired (3 x 333 W = 1000 W). The hotter the element becomes, the less current it draws.
◆ The current draw of each 333 W heating element must not exceed 35A when the heater is switched on.

Audi A6 1998 ➤
80 - Heating
1 - Heater components on vehicle exterior

1.1 - Heater components on vehicle exterior
1 Vent frame for forced air extraction

◆ The sealing lips on the vent frame must be able to move freely and close by themselves (Checking
=>Page 30Protected
). by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note: with respect to the correctness of information in this document. Copyright by AUDI AG.
In order for the vehicle interior ventilation to work properly, the air ducts which run through the luggage com‐
partment trim and lead to the two vent frames (under the bumper on the left and right) must be unobstructed.
1.1 - Heater components on vehicle exterior 27

Audi A6 1998 ➤
2 Ambient temperature switch -F38

◆ Only fitted on 4-cylinder diesel models
◆ The control unit in the 4-cylinder diesel engine is unable to process the ambient temperature signal from
the dash panel insert. The ambient temperature switch is fitted to ensure that the additional heater does
not run continuously at high ambient temperatures.
◆ At ambient temperatures of less than + 6 oC the switch is closed.
◆ Can be tested using "ice" spray.
28 80 - Heating
Audi A6 1998 ➤
3 Fresh/recirculating air flap

◆ Actuated by the positioning motor -V154.
◆ Removing and installing positioning motor =>Page 44 .
4 Dust and pollen filter:
◆ Removing and installing =>Page 30 .
1.1 - Heater components on vehicle exterior 29

Audi A6 1998 ➤
1.2 - Checking vent frame
- -> The sealing lips -B- in vent frame

-A- must move freely and be able to close by themselves
Note:
◆ The illustrations show the vent frame after removal of the rear bumper.
◆ The vehicle is fitted with two vent frames (left and right) for forced air extraction.
◆ In order for the vehicle interior ventilation to work properly, the air ducts which run through the luggage
compartment trim must be unobstructed.
◆ -> Objects placed in the left-hand and right-hand luggage compartment storage boxes may interfere with
the operation of the forced air flow ventilation. This should be checked if problems are reported.
◆ Obstructions in the vent frame -A- may cause the windows to mist up.
1.3 - Removing and installing dust and pollen filter
- Remove plenum chamber cover.
30 80 - Heating
Audi A6 1998 ➤
=> General Body Repairs, Exterior
- -> Release catches on tab -A- and fold back the tab.
- Remove the dust and pollen filter element from its housing.
Note:
◆ To prevent water from entering the dust and pollen filter or the intake duct, make sure that the plenum
chamber cover and cowl panel trim are fitted correctly.
◆ The dust and pollen filter element should be renewed at regular intervals.
=> Workshop Manual, Maintenance booklet
◆ The dust and pollen filter element must be fitted the right way round in frame -C-. Arrows -B- indicate the
direction of air flow.
◆ With additional activated charcoal insert (combined filter).
2 - Heater components in vehicle interior

2.1 - Heater components in vehicle interior
1.3 - Removing and installing dust and pollen filter 31

Audi A6 1998 ➤
Note:
◆ All components marked with an asterisk (*) are actuated during the final control diagnosis =>Page 9 .
◆ An electrical test can be performed on all components marked with a double asterisk (**) =>Page 18 .
◆ Rear centre vent and air ducts in heater and in vehicle interior =>Page 59 .
◆ Remoiving and installing dash panel fascia
1 Bowden cable for left temperature flap

2 Heater element for additional heater -Z35 *

◆ Only on diesel models
◆ Testing operation of electric additional heater =>Page 25 .
3 Heat exchanger
4 Connector for fault reader V.A.G 1551
◆ Connectirng V.A.G 1551 and testing operation of heater=>Page 3 .
5 Dash panel vent , left
32 80 - Heating
Audi A6 1998 ➤
6 Defroster vent for left-hand side window

7 Windscreen defroster vent
2.1 - Heater components in vehicle interior 33

Audi A6 1998 ➤
8 Heater controls with thermotronic control unit -J214

◆ Removing and installing => Page 37 .
◆ Different types depending on whether vehicle has diesel or petrol engine (with and without "Econ" button).
◆ Different types depending on whether vehicles have heater type "1" or type "2" => Page 37 .
◆ Different trim panels depending on whether vehicle has seat heating
◆ Dismantling and assembling =>Page 57by. copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
◆ Removign and installing Bowden cables => Page
permitted unless 39by AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
34 80 - Heating
Audi A6 1998 ➤
Note:
The rotary controls and control buttons are illuminated by LEDs which cannot be renewed. Testing =>Page
18 .
9 Heater
◆ Dismantling and assembling =>Page 69 .
◆ Different types => Page 54
10 Footwell vent
◆ Can only be renewed when the heater is removed.
11 Positioning motor for central flap -V70*
◆ With potentiometer -G112

Audi A6 1998 ➤
12 Bowden cable for right temperature flap

◆ Removing and installing =>Page
permitted 41 . by AUDI AG. AUDI AG does not guarantee or accept any liability
unless authorised
13 Defrost flap positioning motor

-V107 *
◆ Different designs for heater types "1" and "2"
14 Fresh air blower -V2
◆ Different designs for heater types "1" and "2"
15 Dash panel vent, right
36 80 - Heating
Audi A6 1998 ➤
16 Defroster vent for right-hand side window

17 Fresh/recirculated air flap positioning motor -V154 *
◆ No potentiometer fitted. Moves from limit stop to limit stop
18 Series resistor -N24 for fresh air blower
19 Centre dash panel vent
2.2 - Removing and installing heater controls

The set-up for the thermotronic

with respect to thecontrol unit -J214 (incorporated in thebyheater
AUDI AG.controls)
varies. When renewing,
correctness of information in this document. Copyright
therefore, ensure that it is assigned correctly and follow the instructions in the associated Parts List.
=> Parts List

Audi A6 1998 ➤
Note:
◆ In the period from week 36 of 1998 to week 10 of 1999, production will be gradually switched from heater
design "1" to heater design "2". These designs have specific features that differ =>Page 55
◆ Before removing the heater controls, interrogate the fault memory of thermotronic control unit -J214.
◆ After renewing the heater controls, always:
- Perform basic setting
- Interrogate fault memory
◆ If the heater controls are still operational after the ignition has been switched off (i.e. if the positioning motors
still move according to the setting of the air distribution control), test for short circuit to positive in the wiring
to contact 9 on the 16-pin connector (connection for auxiliary heater), using the current flow diagram.
◆ Different types depending on whether vehicle has diesel or petrol engine (with and without "Econ" button).
◆ There are different trim panels depending on whether the vehicle has seat heating. (Dismantling and as‐
sembling heater controls => Page 57 ).
◆ To remove the seat heating switch, dismantle the heater controls =>Page 57 .
◆ If the illumination for the heater controls does not work, test the voltage supply via terminals 58d and 58s
(dimmer) =>Page 18 (Electrical test).
- Remove radio.
=> Electrical system; Repair Group 91
- -> Remove cover and switch panel trim.

- Remove bolts -A-
- -> Remove the front section of the centre console
38 80 - Heating
Audi A6 1998 ➤
- -> Press back catches on connector and detach connector from heater controls.
Detaching and fitting Bowden cables on heater controls
- -> Release Bowden cable mountings -A- using a screwdriver

- Detach Bowden cables -B- from heater controls
Notes on installation:
◆ Check the Bowden cables before fitting, replace stiff or damaged Bowden cables
◆ Fit the wire core the correct way round (with the end of the coil -B- on top).
◆ Bowden cable -C- for left temperature flap
- Colour of mounting: Blue (green for right-hand drive vehicles).
◆ Bowden cable -D- for right-hand temperature flap

- Colour of mounting: Red (yellow for right-hand drive vehicles).
◆ When assembling, secure the Bowden cables with cable ties and clips so that they cannot come into contact
with moving parts.
- -> Fit Bowden cable mounting -A- to heater controls as shown in the illustration.
2.3 - Removing and installing Bowden cable for left-hand temperature flap
Removing
- Remove driver's storage compartment.
2.2 - Removing and installing heater controls 39

Audi A6 1998 ➤
- Remove the front section of the centre console
- -> Detach Bowden cable sheath -C- from cable mounting.

- Carefully detach Bowden cable from lever arm.
- Detach Bowden cable from heater controls => Page 39
Installing
Note:
◆ After installing the Bowden cables, turn the rotary control from limit stop to limit stop (both stops must be
reached).
◆ -> Fit the wire core the correct way round (make sure the end of the coil -A- is not resting against the lever
arm).
- Fit Bowden cable to heater controls => Page 39

- Turn rotary control for left-hand temperature flap to maximum setting for "cold air".
- Fit Bowden cable to lever arm -B- for temperature flap.
- Push down slightly on lever arm -B- for temperature flap in direction of arrow.
- Secure Bowden cable sheath with clip -D-.
- Turn the rotary control for left-hand temperature flap from limit stop to limit stop (both stops must be reached).
40 80 - Heating
Audi A6 1998 ➤
2.4 - Remoiving and installing Bowden cable for right-hand temperature flap
Removing
- Remove glove compartment.
- Remove the front section of the centre console
- -> Detach Bowden cable sheath -C- from cable mounting.

- Carefully detach Bowden cable from lever arm.
- Detach Bowden cable from heater controls => Page 39
Installing
Note:
◆ After installing the Bowden cables, turn the rotary control from limit stop to limit stop (both stops must be
reached).
◆ -> Fit the wire core the correct way round (make sure the end of the coil -A- is not resting against the lever
arm).
- Fit Bowden cable to heater controls => Page 39

- Turn rotary control for right-hand temperature flap to maximum setting for "cold air".
- Fit Bowden cable to lever arm -B- for temperature flap.
- Push down slightly on lever arm -B- for temperature flap in direction of arrow.
- Secure Bowden cable sheath with clip -D-.
- Turn the rotary control for right-hand temperature flap from limit stop to limit stop (both stops must be
reached).
2.4 - Remoiving and installing Bowden cable for right-hand temperature flap 41
Audi A6 1998 ➤
2.5 - Removing and installing series resistor -N24 for fresh air blower
- -> Unplug connector.

- Remove bolt -A-
- Remove series resistor -B- in direction of arrow.
2.6 - Removing and installing fresh air blower -V2
- -> Unplug connector -A-

- Remove bolts -B-
- Remove fresh air blower -C- from heater in direction of arrow.
Note:
The fan wheel of the fresh air blower installed in the type "2" heater is approx. 10 mm shorter than that in the
type "1" heater.
42 80 - Heating
Audi A6 1998 ➤
2.7 - Removing and installing defrost flap positioning motor -V107

- -> Unplug connector -A-.
- Remove screws -B- (3x)
- Disengage actuating arm and take out positioning motor
- Remove bolts -C- (3x) and detach positioning motor -B- from bracket -D-.
Note:
The lever arm on the positioning motor fitted to the type "2" heater is different from that fitted on the type "1"
heater.
◆ After installing, always perform self-diagnosis of heater (=>Page 3 ).
◆ When installing the positioning motor, make sure that the actuating arm is properly engaged.
◆ Fit the wiring harness so that it cannot come into contact with moving parts (e.g. the positioning motor lever)
2.8 -permitted
Removing andbyinstalling
unless authorised AUDI AG. AUDIcentral
AG does not flap positioning
guarantee motor -V70
or accept any liability
- -> Unplug connector -A-.

- Remove bolts -B- (3x)
- Carefully disengage coupling rod -C- with screwdriver -D- and take out positioning motor.
◆ Wen installing the positioning motor, make sure
2.7 - Removing and installing defrost flap positioning motor -V107 43

Audi A6 1998 ➤
that the coupling rod is properly engaged.

◆ When fitting the positioning motor, make sure that the locating pin on the actuating arm engages properly
in the cam plate.
2.9 - Removing and installing fresh/recirculated air flap positioning motor -V154
- -> Unplug connector -C-.

- Remove bolts -A- (3x)
- Take out positioning motor

◆ When fitting the positioning motor, make sure that the locating pin -B- engages properly in actuating arm -
D-.
2.10 - Making special tool for removing dash-panel vents
- -> Bend a piece of wire (3 mm diameter) as shown.

- Dimension x = 12 mm
- Use a hammer to flatten the angled piece to a width of y = 2 mm.
44 80 - Heating
Audi A6 1998 ➤
2.11 - Removing and installing centre dash-panel vent
- Remove trim strip for dash panel
Note:
-> The dash panel vent -1- is secured in the dash panel with spring clips -4-.
- Open the vents -2-.
- -> Insert special tool -A- in dash panel vent and turn to disengage the retainers.
- Use screwdriver -B- to prevent the retainers from engaging again.
Note:
If it is not possible to disengage the lower retainers from the front:
- Remove the whole centre section of the dash panel and also the reinforcement bracket.
2.10 - Making special tool for removing dash-panel vents 45

Audi A6 1998 ➤
- Disengage lower retainer with screwdriver -C-.

-> Take vent out of dash panel from the front. If necessary, use a screwdriver -3-.
2.12 - Removing and installing left-hand dash-panel vent
- -> Insert special tool -A- in dash panel vent and turn to disengage the upper retainers.
- Use screwdriver -B- to prevent the upper retainers from engaging again.
- Take vent out of dash panel from the front.
46 80 - Heating
Audi A6 1998 ➤
2.13 - Removing and installing windscreen defroster vent
- Remove dash panel fascia.

=> General body repairs, Interior; Repairpermitted
Group 70
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
- -> Remove speed nuts -A- and defroster vent -B- from dash panel fascia.
2.14 - Removing and installing right-hand dash-panel vent
- Remove trim strip for dash panel
- -> Insert special tool -A- in dash panel vent and turn to disengage the upper retainers.
- Use screwdriver -B- to prevent the upper retainers from engaging again.
- Take vent out of dash panel from the front.
2.12 - Removing and installing left-hand dash-panel vent 47

Audi A6 1998 ➤
2.15 - Removing and installing left-hand and right-hand side window defroster vents
- -> Carefully lever out of dash panel with screwdriver -A-.
2.16 - Removing and installing heater element for additional heater -Z35
- Remove the whole centre section of the dash panel and also the reinforcement bracket.
- -> Remove left-hand dash panel support by unscrewing bolt -A-, bolts -B- (2x) and bolts -C- (2x).
- Detach wiring harness -D- from left-hand dash panel support.
48 80 - Heating
Audi A6 1998 ➤
- -> Unplug connectors -A-, -B- and -C-.
Note:
◆ All air distributor housings supplied as replacement parts have an opening to accommodate the heater
element for the additional heater. On vehicles with no additional heater, this opening must be closed off with
a cover.
◆ Testing operation of electric additional heater =>Page 25 .
- -> Remove screws -A- and pull additional heater element -B- out of heater.
Note:
◆ The illustration shows the additional heater element after the heat exchanger has been removed.
◆ Insert additional heater element -B- in recesses -C- (with rubber mountings -D- fitted onto pins -E-).
2.17 - Remoiving and installing heat exchanger

- Remove plenum chamber cover.
- Disconnect and remove battery.
Note:
◆ If necessary, obtain radio code before disconnecting

Protected by copyright. Copying battery.
for private or commercial purposes, in part or in whole, is not
◆ In vehicles with electrically adjustable
permittedseats, move by
unless authorised the
AUDIseats back
AG. AUDI AG asdoesfar as possible
not guarantee before
or accept disconnecting
any liability
the battery. with respect to the correctness of information in this document. Copyright by AUDI AG.
◆ Vehicles built up to October 1998
2.16 - Removing and installing heater element for additional heater -Z35 49
Audi A6 1998 ➤
- Remove the windscreen wiper complete.

- Remove grommet (in the opening of the plenum chamber cross panel).
- -> Loosen bolt -A- and unscrew it by 10 mm or remove it completely.
◆ On vehicles built between October 1998 and December 1998
- -> Check whether grommet -A- is present in the opening of the plenum chamber cross panel.
- If grommet -A- is present, remove windscreen wiper complete.
- If grommet -A- is not present, remove dash panel fascia.

Note:
◆ Up until October 1998, the central tube in the dash panel was secured to the body by means of a bolt (to
remove the bolt, the windscreen wiper must be removed).
◆ From October 1998, the fixture for attaching the central tube to the body was gradually changed; it is now
secured by means of a bracket and a bolt on the cross member under the dash panel fascia (to remove it,
the dash panel fascia must be removed).
50 80 - Heating
Audi A6 1998 ➤
◆ Vehicles built from January 1999
- Remove dash panel fascia.
- -> Remove bolt -A-

- Release pressure in coolant system by opening cap on coolant expansion tank.
- -> Clamp off and disconnect both coolant hoses leading to heat exchanger in heater (e.g. using V.A.G 3094).
Note:
◆ The coolant hoses must be refitted in the correct positions:

- Coolant hose -A-: supply hose from cylinder head
- Coolant hose -B-: return hose to water pump
◆ Bleeding the coolant system
=> Engine, Mechanical Components; Repair Group 19
- -> Place a container under connection -B- and carefully blow out the coolant from the heat exchanger (using
compressed air) via connection -A-.
- Remove grommet -C-
- Remove the whole centre section of the dash panel.
2.17 - Remoiving and installing heat exchanger 51

Audi A6 1998 ➤
- -> Detach right-hand dash panel brace from the body by unscrewing bolts -2- (2x).
- -> Unscrew bolts -A- and detach left-hand dash panel brace from the body.
- Removce screws -B- and take off cover -C-
- -> Unscrew bolt -1- and detach pedal bracket from dash panel cross member.
- Push adjustable steering column in as far as it will go.
52 80 - Heating
Audi A6 1998 ➤
- Remove left-hand dash panel cover.
- -> Unscrew bolts -2- far enough to allow the left-hand side of the dash panel module to be pulled back about
10 mm.
- Detach the left-hand side of the dash panel cross member from the body.
- Pull back the left-hand side of the dash panel module far enough to allow the heat exchanger to be taken
out of the heater (past the pedal bracket) and secure the dash panel module in position to prevent it from
sliding back.
- -> Remove screw -A- and take off bracket -B-.

- Release clamps -C-.
- Pull heat exchanger -D- out of heater slightly.
- Pull the two coolant pipes -E- out of the heat exchanger.
Note:
◆ Always renew clamps -C- and O-rings -F-.

◆ Fit both clamps -C- as shown in the illustration, making sure that they are not in contact with the heater.
◆ Before installing the driver's storage compartment, check the cooling system for leaks
◆ Before installing the driver's storage compartment, make sure that the full throttle stop of the accelerator
pedal is fitted in the correct
Protected position.
by copyright. Copying for private or commercial purposes, in part or in whole, is not
◆ On type "2" designs, bracket
permitted unless-B- is not
authorised by present,
AUDI AG. AUDI theAGcover
does notfor the coolant
guarantee pipes
or accept any holds the pipes.
liability
2.17 - Remoiving and installing heat exchanger 53

Audi A6 1998 ➤
3 - Changes to the heating system since 09.98

3.1 - Changes to the heating system since 09.98
In the period from week 36 of 1998 to week 10 of 1999, production will be gradually switched from heater design
"1" to heater design "2". These designs have specific features that differ => Page 55
Note:
If heater components or the heater controls are renewed, the instructions in the associated Parts List must also
be followed.
=> Parts List
The presence of the following vehicle components in the vehicle depends on which type of heater is fitted.
◆ Heater controls with thermotronic control unit -J214
◆ Intermediate piece for defrost duct
- An intermediate piece with two openings to the heater is installed on type "1" heaters.
- An intermediate piece with one opening to the heater is installed on type "2" heaters.
◆ Defrost flap positioning motor -V107
- Heater types "1" and "2" have different designs of lever arm for positioning motor -V107.
◆ Fresh air blower-V2

- The fan wheel of the fresh air blower installed in the type "2" heater is approx. 10 mm shorter than that
in the type "1" heater.
Heater types "1" and "2" have different designs for the following components:
◆ Air distributor housing
- Housing
- Air is ducted to the intermediate piece for the defrost duct by means of two openings on type "1", whilst
on type "2", they are combined into one opening.
- Air distribution flaps in the air distributor housing
- Positon of the three air distribution flaps with respect to the dash panel vents.
- On type "2", both outer flaps remain open slightly at the top when the centre flap is closed (angle between
the flaps is approx. 40 degrees), so that there is always air flowing to the left and right-hand dash panel
vents.
- On design "1", all Protected
three flaps close
by copyright. completely.
Copying for private or commercial purposes, in part or in whole, is not
◆ Air duct with intake housing
- The air duct has been adapted to the modified fresh air blower.
- The fan wheel of the fresh air blower installed in the type "2" heater is approx. 10 mm shorter than that
- The air duct in type "2" is narrower in the area downstream of the fresh air blower, than it is in type "1".
54 80 - Heating
Audi A6 1998 ➤
3.2 - Visible differences between heater types "1" and "2"
Features that are visible when the heater is installed:
- Removing dust and pollen filter =>Page 30 .
◆ -> Intake housing and fresh air blower on type "1"

- The air duct -A- is visible through the fresh air intake opening
◆ -> Intake housing and fresh air blower on type "2"

- There is no air duct fitted:
◆ -> Air duct on type "1"
3.2 - Visible differences between heater types "1" and "2" 55

Audi A6 1998 ➤
◆ -> Air duct on type "2"

- The air duct is narrower in area -A-, than it is in type "1".
- Bracket -B- stands out more than it does on type "1".
Additional features that are visible when the dash panel fascia is removed:
◆ -> Air distributor housing on type "1"

- Air is ducted to the intermediate piece for the defrost duct by means of two openings -A-.
- Air guide flaps -B- close simultaneously and completely.
- Flaps -A-, -B- and -C- are made from sheet steel.
◆ -> Air distributor housing on type "2"

- Air is ducted to the intermediate piece for the defrost duct by means of one opening -A-.
- Flaps -C- remain open slightly at the top when flap -B- is closed (angle between the flaps is approx. 40
degrees).
- Flaps -A-, -B- and -C- are made from plastic.
56 80 - Heating
Audi A6 1998 ➤
4 - Dismantling and assembling heater controls

4.1 - Dismantling and assembling heater controls
Removing and installing heater controls =>Page 37 .
Note:
To preventProtected
damaging the rotary
by copyright. Copying controls
for private orwhen pulling
commercial them
purposes, off,
in part or inplace
whole, isanot
cloth between the control knob and the
jaws of the permitted
pliers or use
unless pliersbywith
authorised AUDIplastic
AG. AUDIorAGrubber jaws. or accept any liability
does not guarantee
1 Rotary control for left-hand temperature flap

2 Rotary control for fresh air blower speed
4.1 - Dismantling and assembling heater controls 57

Audi A6 1998 ➤
3 Rotary control for air distribution control

4 Rotary control for right-hand temperature flap
5 Trim
◆ Different types depending on whether vehicle has seat heating
6 Switch for seat heating
7 Heater control
◆ With thermotronic control unit -J214
◆ Different types depending on whether the vehicle has a petrol engine (no "Econ" button) or diesel engine
(with "Econ" button).
◆ Different types depending on whether vehicles have heater type "1" or type "2"=> Page 37 .
58 80 - Heating
Audi A6 1998 ➤
5 - Air duct in heater and in vehicle interior

5.1 - Air duct in heater and in vehicle interior
Note:
◆ From September 1998, production was gradually switched from type "1" heater design to type "2"=> Page
54 .
◆ The type "1" air ducting system by means of air flaps in the air distributor housing was changed on type "2".
5.2 - Air duct in heater

A- Plenum chamber/dust and pollen filter
B- Front passenger's footwell
C- Fresh air blower -V2
5.1 - Air duct in heater and in vehicle interior 59

Audi A6 1998 ➤
D - Noise insulation
◆ Different air distributor housing designs for heater types "1" and "2"
E - Heat exchanger
F - Heater element for additional heater -Z35
◆ Only on diesel models
G - Division between driver's side and passenger's side
H - To the dash panel vents
◆ Position of the central flaps with respect to each other has changed (see central flap)
60 80 - Heating
Audi A6 1998 ➤
J - To the windscreen vents

◆ Air is ducted to the intermediate piece for the defrost duct by means of two openings on type "1", whilst
K - To the rear footwell vents
L - To footwell vent
M - Wire mesh
1 Fresh/recirculating air flap

2 Temperature flap 1
◆ One flap for driver's side and one for passenger's side
5.2 - Air duct in heater 61

Audi A6 1998 ➤
3 Temperature flap 2
◆ One flap for driver's side and one for passenger's side
4 Central flap
◆ On type "2", both outer flaps remain open slightly at the top when the centre flap is closed (angle between
the flaps is approx. 40 degrees); on type "1", all flaps are closed evenly.
5 Defrost flap
6 Footwell flap
62 80 - Heating
Audi A6 1998 ➤
5.3 - Air ducts in vehicle interior
1 Intermediate piece for defrost duct

◆ Can only be renewed if the dash panel cross member has been removed.
◆ Different designs; the air is ducted from the heater by means of two openings on type "1", whilst on type
"2", these have been combined into one opening.
2 Heater
3 Air duct to right-hand dash panel vent
4 Air duct to left-hand dash panel vent
5.3 - Air ducts in vehicle interior 63

Audi A6 1998 ➤
5 Central air duct

◆ The position of the central flaps is different; on type "2", both outer flaps remain open slightly at the top
when the centre flap is closed (angle between the flaps is approx. 40 degrees), on type "1", all flaps are
closed evenly.
6 Right-hand connecting duct
◆ Fixed to the centre section of dash panel
7 Left-hand connecting duct
◆ Fixed to the centre section of dash panel
64 80 - Heating
Audi A6 1998 ➤

◆ Fixed to the dash panel centre section trim.
◆ Fixed to the dash panel centre section trim.
10 Protected
Rear centre air Copying
by copyright. duct for private or commercial purposes, in part or in whole, is not
◆ Fitted in centre console
11 Intermediate piece for rear centre vent
12 Rear centre vent
◆ Pull out of centre console using special tool
13 Footwell vent
◆ Can only be renewed when the heater is removed.
5.3 - Air ducts in vehicle interior 65

Audi A6 1998 ➤

16 Rear footwell vent, passenger's side
17 Rear footwell vent, driver's side
6 - Removing and installing heater (complete)

6.1 - Removing and installing heater (complete)
- Remove dust and pollen filter and its holder =>Page 30 .
- Disconnect and remove battery.
Note:
◆ If necessary, obtain radio code before disconnecting battery.
66 80 - Heating
Audi A6 1998 ➤
◆ In vehicles with electrically adjustable seats, move the seats back as far as possible before disconnecting
the battery.
- Release pressure in coolant system by opening cap on coolant expansion tank.

- -> Clamp off and disconnect both coolant hoses leading to heat exchanger in heater (e.g. using V.A.G 3094).
Note:
◆ The coolant hoses must be refitted in the correct positions:
- Coolant hose -A-: supply hose from cylinder head
- Coolant hose -B-: return hose to water pump
◆ Bleeding the coolant system
=> Engine, Mechanical Components; Repair Group 19

- -> Place a container under connection -A- and carefully blow out the coolant from the heat exchanger (using
compressed air) via connection -B-.
- Remove grommet -C-
- Remove driver's storage compartment, centre console and dash panel fascia.
6.1 - Removing and installing heater (complete) 67

Audi A6 1998 ➤
- Remove heater controls =>Page 37 .

- -> Remove dash panel cross member -A-
Note:
The dash panel cross member is secured to the windscreen cross member by means of an additional bolt =>
Page 49 .
- Disconnect all the electrical connections between body and heater -B- at the connectors.
Note:
Before unplugging, mark the connectors to the various positioning motors so that they do not get mixed up
when reconnecting.
- -> Remove heater -B-.
Note:
From September 1998, production was gradually switched from type "1" heater design to type "2"=> Page
54 .
◆ Check all seals on the heater for damage before installation and replace any damaged seals.
◆ After assembling, all cable ties that were removed in order to take out the heater must be refitted in their
original positions.
68 80 - Heating
Audi A6 1998 ➤
7 - Dismantling and assembling heater

7.1 - Dismantling and assembling heater
- Remove heater =>Page 66 .
Note:
From September 1998, production was gradually switched from type "1" heater design to type "2" => Page
54 .
1 Bolt
2 Footwell vent
3 Air distributor housing
◆ With heat exchanger
◆ Types "1" and "2" have different designs for the housing, the air flaps and various other components.
7.1 - Dismantling and assembling heater 69

Audi A6 1998 ➤
when the centre flap is closed (angle between the flaps is approx. 40 degrees); on type "1", all flaps are
closed evenly.
4 Combi bolt
70 80 - Heating
Audi A6 1998 ➤
5 Air duct with intake housing

◆ The fan wheel of the fresh air blower installed in the type "2" heater is approx. 10 mm shorter than that
◆ The air duct in type "2" has been adapted to the modified fresh air blower.
◆ The air duct in type "2" is narrower in the area downstream of the fresh air blower, than it is in type "1".
7.1 - Dismantling and assembling heater 71

Audi A6 1998 ➤
8 - Dismantling and assembling air distributor housing

8.1 - Dismantling and assembling air distributor housing
- Dismantling and assembling heater =>Page 69 .
Note:
54 .
1 Bolt
2 Clips
3 Bottom section of air distributor housing
72 80 - Heating
Audi A6 1998 ➤
4 Noise insulation
5 Positioning motor for central flap -V70
6 Bolt
7 Fastener
◆ For Bowden cable to temperature flap
8 Defrost flap positioning motor
-V107
◆ Heater types "1" and "2" have different designs for the lever arm on the positioning motor .
8.1 - Dismantling and assembling air distributor housing 73

Audi A6 1998 ➤
9 Bolt
10 Bracket for positioning motor -V107
11 Air distributor housing
◆ Do not dismantle further
◆ On vehicles which do not have additional heater element -Z35, the opening for the additional heater
element is closed off. On air distributor housings supplied as replacement parts, the opening is open; if
used on vehicles which do not have the additional heater element, the opening must be closed off with
a cap.
◆ Types "1" and "2" have different designs for the housing, the air flaps and various other components.
74 80 - Heating
Audi A6 1998 ➤
when the centre flap is closed (angle between the flaps is approx. 40 degrees), on type "1", all flaps are
closed evenly.

Audi A6 1998 ➤
12 Coolant pipe
◆ Return pipe
13 Coolant pipe
◆ Supply pipe
14 Bracket for coolant pipes
15 Cover
◆ On type "2" with bracket for coolant pipes
16 Bracket for coolant pipes
◆ Only present on type "1".
17 Clamp
◆ Renew
◆ Ensure it is seated properly
18 O-ring
◆ Renew
19 Heat exchanger
76 80 - Heating
Audi A6 1998 ➤
20 Heater element for additional heater -Z35

◆ Only on diesel models (optional on vehicles with auxiliary heater, depending on equipment fitted).
◆ Function, removing and installing => Page 48 .
21 Cap
◆ Only on vehicles with no heater element for additional heater.
◆ The cap is the same as the cap for the heater element for additional heater, except that the openings for
the connectors are sealed air-tight.
22 Rubber mounting

Audi A6 1998 ➤
9 - Dismantling and assembling air duct with intake housing

9.1 - Dismantling and assembling air duct with intake housing
- Dismantling and assembling heater =>Page 69 .
Note:
54 .
1 Bolt
2 Series resistor -N24 for fresh air blower
78 80 - Heating
Audi A6 1998 ➤
3 Screw Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
4 Fresh air blower -V2 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
◆ The fan wheel of the fresh air blower installed in the type "2" heater is approx. 10 mm shorter than that
5 Air duct
◆ The air duct in type "2" has been adapted to the modified fresh air blower.
◆ The air duct in type "2" is narrower in the area downstream of the fresh air blower, than it is in type "1".
9.1 - Dismantling and assembling air duct with intake housing 79

Audi A6 1998 ➤
6 Intake duct
◆ With fresh/recirculated air flap
7 Foam seal
◆ Forms a seal between intake housing and vehicle body.
8 Screw
9 Fresh/recirculated air flap positioning motor -V154
◆ No potentiometer fitted. Moves from limit stop to limit stop
80 80 - Heating

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Service

Service Department. Technical Information

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Copyright © 2010 Audi AG, Ingolstadt A0056007820

01 - Self-diagnosis, Electrical check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

10.1 Electrical test of rear window heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

2.17 Remoiving and installing heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

01 - Self-diagnosis, Electrical check

1 - Self-diagnosis of heating system

fault reader V.A.G 1551

vehicle system tester V.A.G 1552

vehicle diagnostic, testing and information system VAS 5051.

Notes on fault handling:

1.1 - Self-diagnosis of heating system 1

1.3 - Technical data for self diagnosis

▪ Memory Non-volatile memory

◆ Fitting locations of components => Pages 32 .

2 01 - Self-diagnosis, Electrical check

1.4 - Test requirements for self-diagnosis

1.5 - Safety notes

2 - Connecting vehicle diagnostic, measuring and information system VAS 5051

- Switch off ignition.

1.3 - Technical data for self diagnosis 3

-> Display readout:

- Switch on ignition and/or start the engine.

-> Display readout:

-> Display readout:

- Confirm entry with Q key.

-> Indicated on display after address word 08 has been entered:

4 01 - Self-diagnosis, Electrical check

=> Parts List

Summary of functions Page

-> Indicated on display (function selection, e.g. 02 - Interrogate fault memory):

◆ Pressing the HELP key prints a summary of the possible functions.

-> Use current flow diagram to check wiring

reader V.A.G 1551 and selecting function 5

-> Indicated on display after address word 08 has been entered:

-> The control unit identification will be displayed:

-> Indicated on display (function selection, e.g. 02 - Interrogate fault memory):

3 - Interrogating fault memory

-> Display readout (function selection):

-> Display readout:

- Confirm entry with Q key.

- Press the ⇒key.

The stored faults are displayed and printed out

6 01 - Self-diagnosis, Electrical check

Rapid data transfer HELP

- End output (function 06) =>Page 13 .

- 5. Interrogate fault memory (function 02).

3.1 - Interrogating fault memory 7

Output on printer of V.A.G 1551 Possible fault cause Fault elimination

1) This fault is only detected during basic setting.

2) Both limit stops must be reached.

Output on printer of V.A.G 1551 Possible fault cause Fault elimination

8 01 - Self-diagnosis, Electrical check

Output on printer of V.A.G 1551 Possible fault cause Fault elimination

1) This fault is only detected during basic setting.

2) Both limit stops must be reached.

Output on printer of V.A.G 1551 Possible fault cause Fault elimination

5 - Final control diagnosis

◆ Fitting locations of the actuated components =>Page 32 .

Starting the final control diagnosis.

- Connect fault reader V.A.G 1551,