REFRIGERANT LINES WITH INNER HEAT EXCHANGER, REMOVING AND INSTALLING, Vehicles with 2.0L Hybrid: Removing
-- Turn off the ignition.
-- Discharge the refrigerant circuit. Refer to USING SERVICE STATION . For additional information, refer to OVERVIEW - REFRIGERANT CIRCUIT, NOT OPENING THE REFRIGERANT CIRCUIT, VEHICLES WITH HIGH VOLTAGE SYSTEM and OVERVIEW - REFRIGERANT CIRCUIT, OPENING THE REFRIGERANT CIRCUIT, VEHICLES WITH HIGH VOLTAGE SYSTEM (Refrigerant R134a, Servicing; Refrigerant Circuit, Using Service Station).
Depending on the allocation of the service connection to the refrigerant line and vehicle version, it may be necessary to remove the left additional reinforcement on the tower brace so that the service coupling of the A/C service station can be connected (for example, on the Audi Q5). Refer to OVERVIEW - SUSPENSION STRUT WITH MOUNTING BRACKET, SHOCK ABSORBER FORK, UPPER CONTROL ARM AND TOWER BRACE and USING SERVICE STATION (Refrigerant R134a, Servicing; A/C System General Information).
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 .
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" (refer to PERFORMING A VISUAL INSPECTION OF DAMAGE TO HIGH VOLTAGE COMPONENTS AND CABLES ) and "always follow the warnings when working on the high voltage system". Refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .
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.
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.
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 .
High Voltage System,
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.
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
-- Remove the rubber seal -A- and plenum chamber cover -B- (different versions). Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .
- 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 and HIGH VOLTAGE SYSTEM GENERAL WARNINGS .
-- De-energize the high voltage system. Refer to HIGH VOLTAGE SYSTEM, DE-ENERGIZING .
-- 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 .
- 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 and HIGH VOLTAGE SYSTEM GENERAL WARNINGS .
-- 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 PANELS, FUSE PANELS AND E-BOXES .
-- Remove the high voltage cables to the Electric Drive Power and Control Electronics -JX1-. Refer to OVERVIEW - HIGH VOLTAGE CABLES and HIGH VOLTAGE SYSTEM GENERAL WARNINGS .
-- 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 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-.
- Be careful not to damage any high voltage components -D- or the high voltage cables -E-. Refer to HIGH VOLTAGE SYSTEM GENERAL WARNINGS .
To remove and install the refrigerant line with the inner heat exchanger, it may be necessary to remove the cowl panel trim -C-. Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .
From MY 2010, refrigerant lines with an inner heat exchanger -A- that have an additional weight (balance) -B- to reduce noise are being installed on certain versions and depending on the engine. When installing refrigerant lines with an inner heat exchanger -A- and the front wall of the plenum chamber, make sure the weight -B- and the refrigerant lines -A- are not too close or touching the other components.
-- Remove the refrigerant line from the quick-release coupling connections. Refer to REFRIGERANT LINES, DISCONNECTING FROM QUICK-RELEASE COUPLINGS AND CONNECTING .
Close all open lines and connections on the refrigerant line with suitable caps (avoid dirt and moisture from entering the system).
-- Detach the plenum chamber front wall -A- from the vehicle. Refer to OVERVIEW - BULKHEAD .
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.
-- Disengage the catches -arrows A- and remove the upper part of the line pass-through -2- upward -arrow B-.
Disregard item -1-.
-- Loosen the wiring harness from the lower part of the line pass-through -2- and remove the lower part.
-- Remove the nut -C- on the suspension strut tower.
-- Remove the bolts -A-.
-- Disconnect the refrigerant line -B- with the inner heat exchanger from the expansion valve.
Seal the open connections on the refrigerant line and on the expansion valve with suitable caps (to prevent dirt and moisture from entering the system).