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Home >> Audi >> 2008 >> A5 Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 529 (Heating, Ventilation & Air Conditioning (2 Of 2) (Sedan)) >> 87 Air Conditioning >> Front Heater And A/C Unit >> Heater Core, Preparing For Removal

Heater Core, Preparing For Removal

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-- Turn on the ignition.

-- Set the airflow direction to "DEF" (toward the windshield) on the Climatronic Control Module -J255- display and control head.

-- Move the passenger seats as far back as possible.

-- Turn off the ignition.

Vehicles with a high voltage system (Hybrid vehicles) 

Observe all of the additional warnings for all work performed on vehicles with the high voltage system. Refer to HIGH VOLTAGE VEHICLES SAFETY PRECAUTIONS and HIGH VOLTAGE SYSTEM GENERAL WARNINGS for Hybrid .

WARNING:

Risk of unintended engine start

The ignition must be turned off and the ignition key must remain outside of the vehicle when working on vehicles with a high voltage system.

WARNING:

Handling high voltage cables:

  • Do not stand on or place tools on high voltage cables and their components as it may damage the cable insulation.
  • Never bend or kink high voltage cables forcefully as it may damage the cable insulation.
  • The round high voltage connectors are color coded with an external color ring and are mechanically coded using the guide- or code tabs. Always make certain that the coding matches when connecting the round connector in order to avoid any mechanical damage the high voltage connector.
CAUTION:

There is a risk of electrocution from damaged high voltage components.

Observe the following when working around high voltage components and high voltage wires:

  • Never work around high voltage components and cables with cutting, deformed, or sharp edged tools, or heat sources such as welding or soldering tools, heated air, and thermal glue.
  • Inspect the high voltage components visually before beginning.
  • Perform a visual inspection of the Electric Drive Power and Control Electronics -JX1-, the Electro-Drive Drive Motor -V141-, the Electrical A/C Compressor -V470- and the high voltage lines when working in the engine compartment.
  • Perform a visual inspection of the high voltage lines and covers when working on the underbody.
  • Perform a visual inspection of the high voltage lines and the Electrobox with the High Voltage System Maintenance Connector -TW- when working in the luggage compartment.
  • Perform a visual inspection on all of the potential equalization cables.

Observe the following items when performing the visual inspection:

  • The components do not display any signs of external damage.
  • The high voltage cable insulation and the potential equalization cables are not damaged.
  • The high voltage cables do not display any abnormal deformations.
  • Every high voltage component is marked with a red warning label.

De-energize the high voltage system to perform the necessary work on the high voltage system for the following procedure. Refer to HIGH VOLTAGE SYSTEM, DE-ENERGIZING and "read and follow the high voltage electrical system general warnings" in HIGH VOLTAGE SYSTEM GENERAL WARNINGS for Hybrid .

-- De-energize the high voltage system. Refer to HIGH VOLTAGE SYSTEM, DE-ENERGIZING .

High Voltage System, Turning Off Voltage

CAUTION:

Risk of electrocution

Death or serious bodily injury by electric shock.

  • The high voltage system may only be activated by qualified personnel (Audi high voltage mechanic).
  • Make sure that the high voltage system is completely disabled. Make sure the vehicle is de-energized using "Guided Fault Finding  " on the Vehicle Diagnostic Tester.
  • The qualified personal (Audi high voltage technician) determines the voltage and secures the system from restarting using the Service Disconnect Lock T401262. Keep the ignition key and the High Voltage System Maintenance Connector -TW- safely with the qualified personal to secure the system from restarting.
  • The Audi high voltage technician should put a sign on the vehicle to identify it as a high voltage vehicle.
NOTE:

Disable the high voltage system:

Connect the vehicle diagnostic tester.

Select the Guided Fault Finding  mode.

Using the GO TO  button, select the following menu commands

Function/Component Selection 

Body 

Electrical Equipment 

OBD-capable systems 

8C - Battery Regulation Control Module -J840 

8C - Battery Regulation Control Module, functions 

51 - De-energize the high voltage 

-- Disconnect the ground connection from the Battery -A-. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Remove the rubber seal -A- and plenum chamber cover -B- (different versions). Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .

Fig 1: Identifying Plenum Chamber Cover And High Voltage Components
GWWA87-11116Courtesy of AUDI OF AMERICA, LLC

-- Remove the cowl panel trim -C-. Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .

-- Disconnect the ground connection from the Battery -A-. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Loosen the power distribution panel -1- and move it toward the windshield with the wires. Refer to OVERVIEW - RELAY CARRIERS, FUSE PANELS AND E-BOXES and Release Tool Set VAS1978/35 .

Fig 2: Identifying Power Distribution Panel
GWWA93-10008Courtesy of AUDI OF AMERICA, LLC

-- Remove the high voltage cables to the Electrical A/C Compressor -V470- and the Traction Battery -A2- from the Electric Drive Power and Control Electronics -JX1-. Refer to HIGH VOLTAGE CABLES .

-- Cover the Electric Drive Power and Control Electronics -JX1- and related wires to prevent them getting damaged and to protect them from dirt. Refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS for Hybrid .

NOTE:

For example, use clean 20 mm bungs -B- from the Engine Bung Set VAS6122 to seal off the connections on the Electric Drive Power and Control Electronics -JX1- -A-.

Fig 3: Identifying Electric Drive Power And Control Electronics Components
GWWA87-11248Courtesy of AUDI OF AMERICA, LLC

For vehicles without a high voltage system 

-- Remove the plenum chamber cover (not always necessary; there are different versions). Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .

-- Disconnect the ground connection from the Battery -A-. Refer to BATTERY, DISCONNECTING AND CONNECTING .

NOTE:

Disconnect the Battery -A- ground connection so that it cannot short circuit when the jumper cable post -C- is removed.

Fig 5: Identifying Battery (+) Cable, Coolant Hoses And Plenum Chamber Grommet
GWWA87-10515Courtesy of AUDI OF AMERICA, LLC

-- Remove the jumper cable post cover -C-.

-- Remove the jumper cable post -C- from the tower brace and move it to the side. Refer to OVERVIEW - RELAY CARRIERS, FUSE PANELS AND E-BOXES and Release Tool Set VAS1978/35 .

All vehicles 

-- Remove the air intake housing. Refer to HEATER AND A/C UNIT AIR INTAKE HOUSING, REMOVING AND INSTALLING .

-- Remove the connector from the Evaporator Vent Temperature Sensor -G263-. Refer to Evaporator Vent Temperature Sensor -G263-, REMOVING AND INSTALLING .

-- Remove the right radiator housing. Refer to RIGHT RADIATOR HOUSING, REMOVING AND INSTALLING (WITH TEMPERATURE DOORS) .

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