Audi A5 B9 Motor for Recirculation Flap - B1092 07 [009] - Mechanical Failure

[jdragon]

I'm working through a couple of errors found in a scan.

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Address 08: Auto HVAC (E87)       Labels:* Redir Fail!
   Part No SW: 8W0 820 043 T    HW: 8W0 820 043 T
   Component: Klima Zone 3  H60 0251
   Coding: 141800295544440D02000100880000000000000000000000000000000000
   Shop #: WSC 56021 002 1048576
   ASAM Dataset: EV_AirCondiBHTCAU491 001013
   ROD: EV_AirCondiBHTCAU491.rod
   VCID: 44D143C82E1B0FFBABA-8010

   Fresh air blower control module (front):
   Subsystem 1 - Part No SW: 4M2 820 021 A    HW: 4M2 820 021 A
   Component: J126 FLuftV  H08 0003
   Serial number: 00000000000001758876

   Humidity sensor: exterior:
   Subsystem 2 - Part No SW: 4H0 907 658 A    HW: 4H0 907 658 A
   Component: AQ_Hum_Sensor  H01 0006
   Serial number: ADD09EB880PAG0MUFU02

   Rear A/C control head:
   Subsystem 3 - Part No SW: 8W0 919 158     HW: 8W0 919 158
   Component: E265 Kli Fond  H40 0080

1 Fault Found:
328003 - Motor for Recirculation Flap
          B1092 07 [009] - Mechanical Failure
          Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 5
                    Fault Frequency: 1
                    Reset counter: 206
                    Mileage: 113708 km
                    Date: 2022.04.05
                    Time: 12:19:48

                    Recirc. air flap motor: spec.value: 11907
                    Recirculation air flap motor: actual value: 10006
                    System run time-Engine running time: 0 s
                    System run time-Terminal 15 on: 472 s
                    Recirculation air flap motor: diagnostic-Last operating state: No routine started
                    Recirculation air flap motor: diagnostic-Operating condition: Blocking handling
                    Voltage terminal 30: 11.68 V
                    Outside temperature: 14.00 °C


-------------------------------------------------------------------------------

The behaviour I am experiencing is intermittent, regardless of auto or manual mode temperature and air flow speed. What happens is the aircon seemingly goes into 'recirculation mode' shortly after starting a journey with no lights indicating the setting has changed i.e. the flaps at the bulkhead intake close, which throttles the air flow through into the cabin vents. A visual check in this error state has confirmed the flaps at the bulkhead intake are closed, each and every time air flow is restricted into the cabin. Something to note; if I press the windscreen button the air blasts through, but still not through the vents.

If I select 'air con off' the flaps at the bulkhead intake will open (if they are closed with 'air con on') allowing air to flow through the vents - this would be ok if I only wanted warm air.

Something else that happened is the fans were blowing according to the speed level setting I had selected at 20degC but I was getting warm so I reduced the temperature, which in turn reduced the fan/air flow speed into the cabin (the speed level indicator on the display did not change). This seemed repeatable when increasing the temp again, but the air flow speed topped out at 20degC, so I reduced the temperature again down to 17degC in 0.5 increments, and the fan consistently reduced and held at each change, then all of a sudden the air flow speed went back up according to the speed level setting on the display. The next time I was able to pull over and observe the flap positions for each temp setting:

https://imgur.com/Exwefts

https://imgur.com/Iaxq1Jp

http://imgur.com/QZ5PjyK

http://imgur.com/sC9Ul2a

http://imgur.com/uDQMlmf

http://imgur.com/Z6QRVj5

http://imgur.com/Htza5jm

https://imgur.com/IV56m8Y
 

I have found that if I stop and start the car, the behaviour sometimes corrects itself.

In an attempt to resolve this, I cleared the error and did the following with VCDS:

[Select]
[08-HVAC]
[Basic Settings]
[Drop down menu: IDE01546-adapt door end stops]
[Go!]

The routine completed with no errors but still I have the problem (and an additional error code: 65543 - No Basic Setting B2010 09 [009] which just will not clear).

I think I have two options here:

1. Replace the recirculation motor. According to the erWIN Audi repair sheet I downloaded it's 4M0.820.511.A

2. Pull the flaps open essentially mechanically fixing the position, and ignore the error code (I don't use recirculation anyway).

However, if anyone has any suggestions I would be happy to consider them (also posted on Ross-Tech forum).

Edited April 21, 2022 by jdragon
Formatting

[Steve Q]

If you do t use it then you could just leave it. 

With my A6 I've always chosen to carry out the repair. But I fully understand if you don't when you don't use the function. 

[jdragon]

I'd just need to manipulate the setup so the flaps are always open. Should be easy enough. I'm fitting a honeycomb grill tomorrow afternoon, so I'll probably have a look after that if there's enough daylight left 😄 

[Steve Q]

20 minutes ago, jdragon said:

I'd just need to manipulate the setup so the flaps are always open. Should be easy enough. I'm fitting a honeycomb grill tomorrow afternoon, so I'll probably have a look after that if there's enough daylight left 😄 

Good luck, please keep us posted on how you get on 🙂

[Jaime A5 Quattro]

On 4/21/2022 at 9:58 PM, jdragon said:

I'd just need to manipulate the setup so the flaps are always open. Should be easy enough. I'm fitting a honeycomb grill tomorrow afternoon, so I'll probably have a look after that if there's enough daylight left 😄 

Any updates, I seem to have the same problem. Thanks in advance 

[jdragon]

The AC started working fine but only because the flaps had become stuck in the open position.

I was able get this covered under Warranty so the motor was replaced on Friday, now everything is operating as it should.

I found this video which helped:

 

[jdragon]

Something to add for consideration: unless you have the exact code from a scan as I posted above, it could be the fresh air flap motor according to TPI_2058123-2

[Jaime A5 Quattro]

Here’s my error 

Fault Found
328003 - Motor for Recirculation Flap
B1092 07 [009] - Mechanical Failure
Confirmed - Tested Since Memory Clear
Freeze Frame
Fault Status: 00000001
Fault Priority-
Fault Frequency:
Reset counter: 251
Mileage: 53069 km
Date: 2022.05.01
Time: 14:19:40

 

I think we have the same problem? 

[jdragon]

It definitely appears so.

The motor is £219 Inc VAT from Audi. They've updated the part which is indicated by the 'A' at the end of the number 4M0.820.511.A

[Jaime A5 Quattro]

At first I thought the wife was going mad, every time she borrowed my car it seemed to not work until yesterday when it happened to me. Have you replaced one yourself or is it a garage job.

Thanks for your speedy replies hopefully get this sorted before it gets to hot. 

[jdragon]

I thought I was too; my old A4 behaved nothing like this when the same motor failed 😄

It's fully accessible from inside the car without needing to remove anything.

I've got the workshop manual, so I'll attach it later when I'm home.

The flap positions need to be reset when the motor has been installed.

[jdragon]

8 hours ago, Jaime A5 Quattro said:

At first I thought the wife was going mad, every time she borrowed my car it seemed to not work until yesterday when it happened to me. Have you replaced one yourself or is it a garage job.

Thanks for your speedy replies hopefully get this sorted before it gets to hot. 

Here it is 🙂

rec_mot_ins.pdf

[Jaime A5 Quattro]

10 minutes ago, jdragon said:

Here it is 🙂

rec_mot_ins.pdf 398.65 kB · 2 downloads

Brilliant, hopefully I will get this sorted 👍🏻

[jdragon]

Will be interesting to know how you get on.

[Jaime A5 Quattro]

13 hours ago, jdragon said:

Will be interesting to know how you get on.

I will definitely keep you posted, my car needs a service only a oil change doing, I might be cheeky and ask if will also fit a new recirculation flap whilst it’s in. Its not a main dealer I am using but he’s an Audi Specialist obviously his prices are a lot cheaper then Audi itself. 

[jdragon]

It's definitely not a main dealer only task, assuming you have access to VCDS for basic setting 🙂

 

[Deekster]

Hi,

Saw your post which discusses the same issue I have just found on my 2017 S5.

Scan image shown.

I downloaded the manual but was wondering if you had any photos showing the flap motor location?

Thanks

 

[jdragon]

No, I don't have photos. The manual extract posted on May 16th shows where it is.

[Jaime A5 Quattro]

Hi Guys 

I had my car in to Audi Specialist centre near me yesterday and had my flap replaced and basic setting applied for it to function correctly. 
 

The replacement part number was 4mo820511a. 
 

The actual cost was £250 + vat. 

[jdragon]

Great you have this sorted.

Did you buy the part, or the specialist?

[Jaime A5 Quattro]

1 hour ago, jdragon said:

Great you have this sorted.

Did you buy the part, or the specialist?

The specialist source the part from the main dealer hence the price,  I did try and look on eBay out of Curiosity but couldn’t find one. 

[jdragon]

1 hour ago, Jaime A5 Quattro said:

The specialist source the part from the main dealer hence the price,  I did try and look on eBay out of Curiosity but couldn’t find one. 

I heard dealers vary their prices, but I never thought it would be so much! 

[Jaime A5 Quattro]

2 hours ago, jdragon said:

I heard dealers vary their prices, but I never thought it would be so much! 

Snap, I am currently recovering from an operation and thought it would be quick job and costing around £100 how wrong was I 😂 they have just quoted £550 for Cambelt change no sure if that’s a good price ? 

[jdragon]

 

12 hours ago, Jaime A5 Quattro said:

Snap, I am currently recovering from an operation and thought it would be quick job and costing around £100 how wrong was I 😂 they have just quoted £550 for Cambelt change no sure if that’s a good price ? 

Where do you live? Dealers sell the recirculation flap motors for £219 Inc VAT in Cambridge area.

I've not had the cambelt done on mine yet. It's coming up to the 5 year point in September, so I'll have it have it changed then.

My old A4 B8 diesel was around £450 with water pump.

[Jaime A5 Quattro]

40 minutes ago, jdragon said:

 

Where do you live? Dealers sell them for £219 Inc VAT in Cambridge area.

I've not had the cambelt done on mine yet. It's coming up to the 5 year point in September, so I'll have it have it changed then.

My old A4 B8 diesel was around £450 with water pump.

sorry the quote was for Cambelt Kit which includes the water pump.