Those who have/had AC Compressor failure- Info Request

[skotti]

Please post engine type/year/mileage at time of failure; also interested in how you use the Climate Control- ie, always in Automatic, 50-50 in Economy/Automatic, Automatic only when AC is desired, etc.

I haven't experienced this failure (yet)- although if it is going to happen, I'd like it to happen while it is under warranty (bought mine in June 2005 with the 'good' warranty, and currently have 30,000 miles).

Is it a matter of when, not if, the AC compressor will fail
Not that I'm going to force the failure...

[OOOO-A3]

It makes no difference. If you have a Zexel compressor, it has a high probability of failure regardless of how it's used. Some people have had failures in a couple thousand miles after purchase, some longer....

[gsodonis]

I bought mine used, a 2006, 2.0T, DSG with 27,700 miles. I owned it ONE day when the AC stopped working. The compressor was an original Zexel. It took the dealer less than a week to get the parts, and the better part of a week to replace it; I turned in my car on a Wednesday and they needed the car over the weekend. I had a 2006 A4 loaner the whole time, which I didn't like anywhere near as much as my A3.
All of the above were covered under warranty with great treatment by Harper Audi in Knoxville.

My car has a May 2005 build date, so anything that can go wrong on a first production year car either has or will go wrong on mine. My short list:
- failed compressor
- failed #1 ignition coil
- cut CV boots (factory clamps cut into the boot @ the axle end making them leak)
- broken rear armrest latch

On deck (likely):
- DV
- the remaining coils

Modified by gsodonis at 6:33 PM 6/4/2008


Modified by gsodonis at 6:34 PM 6/4/2008

[gsodonis]

Although Audi may never admit it, I belive that they are experiencing almost 100% failure rate on these AC compressors.

[Angel@forgemotorsport.com]

Quote, originally posted by gsodonis »

Although Audi may never admit it, I belive that they are experiencing almost 100% failure rate on these AC compressors.

I hope not. I have an 06 with 15k on it now, bought it a few months ago with 10k on it, and I have a zexel compressor on it still...... that would mean that I'm just waiting to be stuck in traffic with a failure and a ****-ton of fl heat and humidity. As cool as my service advisor is, I doubt that he could get it changed pre-failure.

[dhltal]

I hope not either about the failure rate... I have almost 50k and I doubt this would be fixed if I'm out of warranty range.

[A3Danimal]

How does one know its a Zexel compressor? Does it say that on it somewhere? TIA!

[michA3er]

We were trying to figure out how to tell the Zexel from the Denso on another thread. Both compressors are clutchless, so you can't tell from looking at the pulley. I guess we need the next person who has a failure to get pics of their failed Zexel and the new Denso (both off-vehicle).

[OOOO-A3]

There is a visual identification guide in Audi TB 87-07-02. Click here to download the PDF

[Travis Grundke]

Well, I'm outside of warranty (51,000) and my compressor just failed last week. No doubt I'll be fighting the battle with Audi of America shortly, I'll let you know how it goes.

Should they not cover the compressor they know fails, shame on Audi, and they'll probably lose repeat business from me.

[5309]

engine type:2.0t
year: 2007
mileage: 21XXX
Climate Control: between 60/60 both sides and 64/64
Failed on: 5/28/08 - nothing but HOT air
Brought to dealer: 5/29/2008
Dealer update: 5/29/2008, said they had to order A/C parts from Cail will be in something this week.
Dealer called said it was fixed yesterday: 6/4/2008
We will see as of today if it is fixed..

[Angel@forgemotorsport.com]

The denso will have a black circular piece with small tabs at the 3/6/9 positions suspended on thin metal straps projecting from the main pulley. The zexel has a more or less flat pulley. I'll post pics if you guys want. Just the shot of the pulleys from above so you can tell which you have at a glance.

[michA3er]

Angel, if you could post the pics that would be awesome.

[Angel@forgemotorsport.com]

I'll have them up shortly sir.

[Angel@forgemotorsport.com]

old bad one

new good one

[Angel@forgemotorsport.com]

Old zexel photo is from my 06 a3 and the denso pictured from Mike's 07 gti. The same denso compressor is in our own golfsilvercharged's 07 a3 as well ( verified yesterday ) so there's no gti difference at play here.

[michA3er]

Besides the pulley face differences that you already mentioned I see the shapes of the front head castings are different. Also, the Denso front head has that "S07R" marking, which I assume is a lot number.

[michA3er]

BTW, the Denso's pulley face makes it looked like a non-clutchless compressor. I know it's supposed to be clutchless, but those silver bands connecting to the black triangular part look like a leaf spring mechanism.

[-j-]

Is Sanden also part of this TSB? AudiWorld had it listed with the Zexel.

http://forums.audiworld.com/a3/msgs/93314.phtml

I have to make sure mine is good to go. I'm checking it tonight and having it tested on the next oil change at 45,000 miles.

[ivster]

Mine just failed at 43000 Miles

06 2.0t using the A/C on Auto, was in the Mid 90's on Wed when it happened.


Modified by ivster at 7:29 AM 6/6/2008

[spaner]

Mine just failed at 55,000 - any idea what action I can/should take with Audi - I am in MD but car was purchased new in Ohio

A3 2.0T 2007 MY I think...


Modified by spaner at 3:32 AM 7-10-2009

[thethirdjq]

engine type:2.0t
year: early build 2006
mileage: 89XXX (highway miles)
Climate Control: avg 72 on both sides on econ mostly
Failed on: 6/09 - nothing but HOT air on the hottest day it could have been
Brought to dealer: gave the run around and an estimate of $1700 as a starting point
I took it to a mentor's personal audi mechanic that left the dealership few years ago
Took a week for parts - dropped the car off and took a week to repair - i was out $1300

Due to the known fact of the problems with this compressor and the fact that audi has changed to denso - this should be a recall. Anyone want to start a class action lawsuit? can that be done?

[dmorrow]

Quote, originally posted by thethirdjq »

Due to the known fact of the problems with this compressor and the fact that audi has changed to denso - this should be a recall. Anyone want to start a class action lawsuit? can that be done?

This is a good topic with interesting information but without knowing both failures and non failures I don't really know what it tells us except that there are a lot of failures. I think you would have to have a lot more information to have a lawsuit. Are 40% failing? 60%? I don't think we know and you need everyone or at least most to post what has happened to really tell anything. I am at 80k without a failure and hope to not have one. Since I don't know of anything to do but wait and hope I am not going to worry about it too much.

[ottodc6]

Bought my 06 2.0T at 47000km IN WINTER, so I never got a chance to test out the AC.

Never worked in Summer. Brought it in for warranty and they say the compressor is dead. They flushed & replaced it for free.

[LWNY]

Does this apply to the 3.2 also? My compressor (which is really hard to see), looks like neither of those two. I don't use the AC as much (let alone the car), and don't want it die after warranty expires w/o really giving the compressor a workout that it needs.

[ryamin]

Mine just failed at 71,000 kms. Was pushing nothing but warm air. My factory warrantee is only good until 80,000 kms so I am lucky. Fixed in 2 days by the dealership at no charge.

[Hal_K]

The 2006 3.2 has the Zexel.

[LWNY]

That's bad news. Gotta use it to the max before the warranty runs out.

[skotti]

Quote, originally posted by ivster »

Mine just failed at 43000 Miles 06 2.0t using the A/C on Auto, was in the Mid 90's on Wed when it happened. Modified by ivster at 7:29 AM 6/6/2008

ivester, were you under warranty- if not, did the dealer help you at all?

[tiptronic]

Quote, originally posted by Travis Grundke »

Well, I'm outside of warranty (51,000) and my compressor just failed last week. No doubt I'll be fighting the battle with Audi of America shortly, I'll let you know how it goes. Should they not cover the compressor they know fails, shame on Audi, and they'll probably lose repeat business from me.

Write to Audi directly and ask for help...who knows since you're only 1k over the warranty.... they might cover half the cost, ro cover it entirely!

e

[Travis Grundke]

I was able to get Audi and my dealership to cooperate on the repairs for my car when it failed at around 51,000. It required a call to Audi of America, an email to Audi of America with pages upon pages of documentation from forum discussions such as these, the Audi TSB that is out there, etc. I then printed out the same information for my dealership.

My total out of pocket was very reasonable, though I still think AoA should have foot the entire bill on this one considering how big of an issue this is. A lot of the end result will come from how persistent and how much of an advocate your service department advisor is. Mine at Stoddard/Willoughby Audi is fantastic.

Quote, originally posted by spaner »

Mine just failed at 55,000 - any idea what action I can/should take with Audi - I am in MD but car was purchased new in Ohio A3 2.0T 2007 MY I think... Modified by spaner at 3:32 AM 7-10-2009

[tiptronic]

Quote, originally posted by Angel@forgemotorsport.com »

old bad one new good one

The 2nd pic is what i have in my 07 A3 (Build date 03/07). Can i assume that this is the newer compressor (or more reliable?)

thanks

[OOOO-A3]

The one currently in my car is exactly as pictured below, after all my replacements. The receipt from the dealer explicitly stated "vendor code DENSO".

Quote, originally posted by Angel@forgemotorsport.com »

old bad one

[littlewhite]

07 here low miles. Switch failed earlier this yr and got it replace & said everything function well. Brought paperwork and stacks of printout for the Zexel compressor failure and request them to put in the Denso one since Zexel the failure rate is high. Stealership said wont replace until the units fail... I dont want to wait until it blow into pieces like some member here. Sux


Modified by littlewhite at 5:40 PM 7/11/2009

[dmorrow]

Quote, originally posted by littlewhite »

Brought paperwork and stacks of printout for the Zexel compressor failure and request them to put in the Denso one since Zexel the failure rate is high. Stealership said wont replace until the units fail... I dont want to wait until it blow into pieces like some member here. Sux Modified by littlewhite at 5:40 PM 7/11/2009

Did you really think this this was going to work or was this just fishing for help??