Evaporator, Removing And Installing: Installing

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Before installing the evaporator. Refer to REFRIGERANT CIRCUIT COMPONENTS, REPLACING .

Installation is carried out in the reverse order while observing the following.

-- Check the A/C unit via the evaporator installation shaft for dirt; clean the A/C unit if necessary.

Fig 1: Checking A/C Unit Via Evaporator Installation Shaft For Dirt; Clean A/C Unit If Necessary

Courtesy of AUDI OF AMERICA, LLC

NOTE:

When doing this, pay attention to both condensation water drains -A- and their openings -B-.

-- Check both connections -B- and -C- on the replacement evaporator -A- for dirt and damage.

Fig 2: Checking Both Connections On Replacement Evaporator For Dirt And Damage

Courtesy of AUDI OF AMERICA, LLC

-- Install both covers -D- and -F- on the correct side on the evaporator.

NOTE:

Both covers are included in the replacement evaporator kit .

Depending on the cover version -D- cut the part -E- from this cover (on the side with the connections installed).

-- Push the evaporator -A- into the A/C shaft; when doing this, be careful not to loosen the covers -D- and -F- from the evaporator.

-- Install the bracket -A- with the bolt -B- on the evaporator connector.

Fig 3: Identifying Bolts On Evaporator Connector

Courtesy of AUDI OF AMERICA, LLC

-- Check the refrigerant lines -C- and -D- for damage and dirt.

NOTE:

Even slight damage (a scratch) or a little bit of dirt (a hair) can cause leakage at a connection.

The refrigerant lines -C- and -D-, the o-rings -E- and -F-, the bracket -A- and the bolt -B- and -H- are all included in the replacement evaporator kit .

-- Install the refrigerant lines -C- and -D- into the grommet -G-.

NOTE:

If replacing the evaporator on an Audi Q5 Hybrid, then wrap the refrigerant pipe -C- on the replacement evaporator with insulating tape as illustrated before installing. Approximately 30 cm of 5 cm wide insulating tape (butyl or tar tape) -B- with a 3 mm strength will be needed.

Fig 4: Identifying Refrigerant Pipe Components

Courtesy of AUDI OF AMERICA, LLC

Wrap both ends of the refrigerant pipe -C- when it is removed, as illustrated. Do not wrap approximately 15 mm in area -A-. This is where a grommet will be installed facing the expansion valve. Likewise, do not wrap the connection area to the evaporator.

-- Coat the O-rings -E- and -F- with refrigerant oil before installing. Refer to REFRIGERANT CIRCUIT SEALS .

Fig 5: Identifying Bolts On Evaporator Connector

Courtesy of AUDI OF AMERICA, LLC

-- Mount the O-rings -E- and -F- on the refrigerant lines -C- and -D-.

-- Install the refrigerant lines -C- and -D- in the connection on the evaporator.

-- Install the bolt -H-.

-- Install both bolts -B- and -H- equally far enough so that both refrigerant lines -C- and -D- can be turned without pretension.

NOTE:

When installing the bolts -B- and -H- be careful not to twist the bracket -A- together with the refrigerant lines.

If the refrigerant pipe wrapping -B- touches the separating walls of the evaporator housing -C- on an Audi Q5 hybrid, rework the walls, if necessary.

Fig 6: Identifying Expansion Valve Components

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-- Install the expansion valve retaining plate -A- on the refrigerant lines -B- and -C-.

Fig 7: Identifying Grommet And Plenum Chamber Rear Wall

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-- To align both refrigerant lines, first install the expansion valve (refer to EXPANSION VALVE, REMOVING AND INSTALLING ) and the refrigerant line with the inner heat exchanger (refer to REFRIGERANT LINES WITH INNER HEAT EXCHANGER, REMOVING AND INSTALLING ).

NOTE:

The expansion valve and the refrigerant line the inner heat exchanger are installed first to align both refrigerant lines leading to the evaporator, and after tightening both bolts on the evaporator connect, they are removed again.

-- Tighten the bolts -B- and -H- on the evaporator connector (tightening specification 5 Nm).

Fig 8: Identifying Bolts On Evaporator Connector

Courtesy of AUDI OF AMERICA, LLC

NOTE:

This illustration show the refrigerant pipes -C- and -D- to the evaporator not wrapped with butyl or tar tape.

On the Audi Q5 hybrid, wrap the refrigerant pipe to the evaporator with a piece of butyl or tar tape in area -A- as illustrated after tightening the screws to reduce noise. Then wrap the entire area -D- on the evaporate with another piece of butyl or tar tape.

Fig 9: Identifying Expansion Valve Components

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-- Remove the refrigerant line with the inner heat exchanger and the expansion valve again.

-- Install the expansion valve. Refer to EXPANSION VALVE, REMOVING AND INSTALLING .

-- Install the refrigerant line with inner heat exchanger. Refer to REFRIGERANT LINES WITH INNER HEAT EXCHANGER, REMOVING AND INSTALLING .

-- Install the cover for the evaporator refrigerant lines -B- and the bolt -A-.

Fig 10: Identifying Cover For Evaporator Refrigerant Lines And Bolt

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-- Make sure the cover -B- fits correctly and that it is free of tension.

NOTE:

Even the smallest leak at the groove/spring connection between the cover -B- and the A/C unit -A- will cause whistling noises. Coat the connecting surfaces lightly with silicone grease (part number G 000 405 A2).

Fig 11: Identifying Groove/Spring Connection Between Cover And Air Conditioner

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-- Clean and dry the groove in the A/C unit -E- before installing the separating wall -C-.

Fig 12: Cleaning And Drying Groove In A/C Unit Before Installing Separating Wall

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-- Fill the groove in the A/C unit -E- before installing the separating wall -C-, for example, with Silicone Adhesive D 176 001 A3.

-- Install the separating wall -C-.

NOTE:

The separating wall -C- is included in the replacement evaporator kit .

There are different versions of the separating wall -C- (with and without the sprayed-on sealing lip) .

If the connecting location between the A/C unit -E- and the separating wall -C- is not sealing in area -D- condensation water from the A/C unit could leak into the footwell when, for example, driving around a curve.

-- Remove any excess adhesive (the adhesive may only be in the area -D-); and remove any excess adhesive out of the groove -G-.

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

Vehicles with a high voltage system (Hybrid vehicles)

-- Visually inspect the high voltage components -D- and high voltage cables -E- after completing the work procedures and before installing the plenum chamber cover -B-. Refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS for Hybrid .

Fig 13: Identifying Plenum Chamber Cover And High Voltage Components

Courtesy of AUDI OF AMERICA, LLC

-- Electrical connections and routing. Refer to appropriate SYSTEM WIRING DIAGRAM.

-- Install the remaining removed parts in the opposite order.

-- Energize the power supply to the high voltage system. Refer to HIGH VOLTAGE SYSTEM, RE-ENERGIZING .

Restart the high voltage system

CAUTION:

Risk of electrocution

Death or serious bodily injury by electric shock

The high voltage system may only be restarted by qualified personal (Audi high voltage technicians).
Make sure the vehicle is energized using the "Guided Fault Finding " on the Vehicle Diagnostic Tester.
The qualified personal (Audi high voltage technician) restarts the vehicle.
The Audi high voltage technician should put a sign on the vehicle to identify it as a high voltage vehicle.

NOTE:

Restart 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 - High voltage restart (Repair Group 93)

For vehicles without a high voltage system

-- Reconnect the Battery -A- ground connection; when doing this, pay attention to the notes regarding reconnecting the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Install the remaining removed parts in the opposite order.

All vehicles

-- Evacuate the refrigerant circuit and fill it. Refer to USING SERVICE STATION and REFRIGERANT R134A CAPACITIES, REFRIGERANT OIL AND APPROVED REFRIGERANT OILS (Refrigerant R134a, Servicing; Refrigerant Circuit, Using Service Station).

-- Install the remaining removed components.

-- Turn on the ignition.

-- Perform a basic setting and the output diagnostic test mode for the A/C system using the Vehicle Diagnostic Tester in the "Guided Fault Finding " function.

NOTE:

On this vehicle, the actuators are equipped with electronics. During the basic setting, a new actuator learns its position on the A/C unit and can then be activated by the Climatronic Control Module -J255- A/C display and control head (currently all actuators are identical) using the Vehicle Diagnostic Tester in the "Guided Fault Finding " function.

During the basic setting, the actuators are assigned and adapted corresponding to the switching sequence of the wiring. If this sequence does not conform the specification, the adjustment motors will adapt incorrectly and the door control will be wrong. Refer to MAIN WIRING DIAGRAM FOR A/C SYSTEM ACTUATORS (A/C system actuators block diagram).

-- Check the DTC memory for the Climatronic Control Module -- A/C display and control head and erase any displayed malfunctions, if necessary using the Vehicle Diagnostic Tester in the "Guided Fault Finding " function.

-- Operate the A/C system after filling the refrigerant circuit. Refer to A/C SYSTEM, STARTING OPERATION AFTER FILLING REFRIGERANT CIRCUIT .

NOTE:

Observe the information regarding operating the A/C system after filling. Refer to A/C SYSTEM, OPERATING AFTER CHARGING . After charging the A/C system before activating the A/C system.