Evaporator, Removing And Installing: Removing

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

-- Turn off the ignition.

-- Discharge the refrigerant circuit. Refer to REFRIGERANT CIRCUIT (Refrigerant R134a Servicing, Refrigerant Circuit, Working with A/C Service Station) or WORKING WITH A/C SERVICE STATION .

NOTE:

Depending On The Allocation Of The Service Connection To The Refrigerant Line And Vehicle Version, It May Be Necessary To Remove The Left Auxiliary Reinforcement On The Tower Brace So That The A/C Service Station Service Coupling Can Be Connected (For Example, On The Audi Q5). Refer to OVERVIEW - SUSPENSION STRUT AND UPPER CONTROL ARM and REFRIGERANT CIRCUIT (Refrigerant R134a Servicing, Working with A/C Service Station) or WORKING WITH A/C SERVICE STATION .

ON 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 .

If It Is Necessary For The Following Procedure To Perform Work Near High Voltage Components, "Perform A Visual Inspection Of The High Voltage Components And Cables For Damages" And "Always Follow The Warnings When Working On The High Voltage System". Refer To PERFORMING A VISUAL INSPECTION OF DAMAGE TO HIGH VOLTAGE COMPONENTS AND CABLES .

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 appropriate service information. And "Read And Follow The High Voltage Electrical System General Warnings" in WARNINGS WHEN WORKING ON VEHICLES WITH HIGH VOLTAGE SYSTEM .

-- De-Energize The High Voltage System. Refer To WARNINGS WHEN WORKING ON VEHICLES WITH HIGH VOLTAGE SYSTEM .

High Voltage System,

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:T40262 . 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:

De-Energize The High-Voltage System:

Connect the vehicle diagnostic tester.

Select the Guided Fault Finding Mode.

Using the GO TO Button, Select The Menu Items In The Following Sequence:

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 System (Repair Group 93)

-- 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

Courtesy of AUDI OF AMERICA, LLC

-- Visually inspect the high voltage components -D- (here the Electric Drive Power and Control Electronics -JX1-) and the high voltage cables -E- after removing the plenum chamber cover -B-. Refer to PERFORMING A VISUAL INSPECTION OF DAMAGE TO HIGH VOLTAGE COMPONENTS AND CABLES .

-- 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 E-BOX RELAY AND FUSE PANELS, REMOVING AND INSTALLING .

Fig 2: Identifying Power Distribution Panel

Courtesy of AUDI OF AMERICA, LLC

-- Remove the high voltage cables to the Electric Drive Power and Control Electronics -JX1-. Refer to the appropriate Service Information .

-- 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 WARNINGS WHEN WORKING ON VEHICLES WITH HIGH VOLTAGE SYSTEM .

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

Courtesy of AUDI OF AMERICA, LLC

Be careful not to damage any high voltage components -D- or the high voltage cables -E-. Refer to WARNINGS WHEN WORKING ON VEHICLES WITH HIGH VOLTAGE SYSTEM .

Fig 4: Identifying Plenum Chamber Cover And High Voltage Components
Courtesy of AUDI OF AMERICA, LLC

NOTE:

To Remove And Install The Expansion Valve, It May Be Necessary To Remove The Cowl Panel Trim -C-. Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .

For Vehicles Without A High Voltage System

-- Turn off the ignition.

-- Remove the plenum chamber cover and/or the cowl panel trim (different versions). Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .

-- Disconnect the ground connection from the Battery -A-. Refer to BATTERY .

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

Courtesy of AUDI OF AMERICA, LLC

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

ALL VEHICLES

-- If equipped and necessary, remove the tower brace -B- (for example, on the Audi A5 Coupe; not necessary, for example, on the Audi Q5). Refer to TOWER BRACE

Fig 6: Identifying Suspension Strut Dome

Courtesy of AUDI OF AMERICA, LLC

-- For vehicles with a 6-Cylinder diesel engine, remove the plenum chamber front wall -A-. Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .

NOTE:

On Vehicles With A Gasoline Engine Or A 4-Cylinder TDI Engine, The Plenum Chamber Front Wall Must Not Be Loosen Or Removed From The Vehicle (There Is Enough Space).

On vehicles with a gasoline engine or a 4 cylinder TDI engine, both coolant hoses to the heater core are routed through the plenum chamber front wall -A-. On these vehicles, loosen the grommet on both coolant hoses and move the plenum chamber front wall to the side (when doing this, the refrigerant circuit must not be opened).

When loosening the plenum chamber front wall, be careful not to damage the brake booster vacuum line.

-- For vehicles with a 6-Cylinder TDI engine, remove the plenum chamber front wall -A-. Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .

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

NOTE:

Seal Open Pipe Connections.

-- Remove the expansion valve retaining plate -A- from the refrigerant lines -B and C-.

Fig 7: Coat Grommet With Grease And Install It In Plenum Chamber Rear Wall

Courtesy of AUDI OF AMERICA, LLC

-- Remove the storage compartment under the instrument panel on the driver side. Refer to STORAGE COMPARTMENTS AND COVERS .

-- Remove the left footwell vent (driver side). Refer to DRIVER SIDE FOOTWELL VENT, REMOVING AND INSTALLING .

-- Remove the steering column. Refer to STEERING COLUMN .

-- Remove the pedal assembly and the accelerator pedal module. Refer to the appropriate Service Information and ACCELERATOR PEDAL POSITION SENSORS -G79- / -G185-, REMOVING AND INSTALLING .

-- Remove the bolt -A-.

Fig 8: Identifying Cover For Evaporator Refrigerant Lines And Bolt

Courtesy of AUDI OF AMERICA, LLC

-- Loosen the retainer -C- and remove the cover for the refrigerant lines leading to the evaporator -B-.

-- Disconnect both refrigerant lines to the evaporator -A and B- at the locations marked with -E- using the A/C Pipe Pliers:T40147 .

Fig 9: Disconnect Both Refrigerant Lines Leading To Evaporator Using T40147

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.

The refrigerant pipe -D- on the Audi Q5 Hybrid is wrapped with insulation (butyl or tar tape) to reduce noise. The butyl or tar tape shields the A/C compressor noise, which seems to be louder when the engine is idling.

-- Loosen the disconnected refrigerant lines -C and D- from the grommet -F- and remove both refrigerant lines.

-- Bend the part of the refrigerant line -A- (which is already on the evaporator) to the right (to the evaporator) so that it does not interfere when removing the evaporator.

-- Remove the glove compartment. Refer to GLOVE COMPARTMENT, REMOVING AND INSTALLING .

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

-- Cut the housing wall -A- (on the right side of the A/C unit) using a sharp knife (for example, a strong carpet knife with a point; the blade must be secure and the handle must be strong.) along the marked cutting line from the A/C unit.

Fig 10: Clean And Dry Groove In A/C Unit Before Installing Separating Wall

Courtesy of AUDI OF AMERICA, LLC

-- Remove the evaporator -B- in the direction of the -arrow- from the A/C unit.