REFRIGERANT LINES, DISCONNECTING AND CONNECTING AT A/C COMPRESSOR, Vehicles with 2.0L: 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 WITHOUT HIGH VOLTAGE SYSTEM and OVERVIEW - REFRIGERANT CIRCUIT, OPENING THE REFRIGERANT CIRCUIT, VEHICLES WITHOUT 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 . For additional information, refer to OVERVIEW - REFRIGERANT CIRCUIT, NOT OPENING THE REFRIGERANT CIRCUIT, VEHICLES WITHOUT HIGH VOLTAGE SYSTEM and OVERVIEW - REFRIGERANT CIRCUIT, OPENING THE REFRIGERANT CIRCUIT, VEHICLES WITHOUT HIGH VOLTAGE SYSTEM (Refrigerant R134a, Servicing; Refrigerant Circuit, Using 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 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.
-- Remove the bolts -1- and -4-.
-- Remove the refrigerant pipes.
For vehicles without a high voltage system
- Remove the A/C Compressor from the bracket (only if the refrigerant lines cannot be removed when the A/C Compressors connected). Refer to A/C COMPRESSOR, REMOVING AND INSTALLING ON BRACKET .
On vehicles with a 4-Cylinder engine, it is not always necessary to remove the A/C compressor from the bracket in order to remove the refrigerant lines. Depending on the style of the power steering vane pump, the refrigerant lines can be removed form the A/C compressor also when the A/C compressor is removed from the bracket.
The power steering pump is only installed on vehicles without electromechanical power steering. Refer to appropriate power steering components in POWER STEERING PUMP, REMOVING AND INSTALLING, VEHICLES WITH DYNAMIC STEERING - Vehicles with 4-Cylinder TFSI Engine or POWER STEERING PUMP, REMOVING AND INSTALLING, VEHICLES WITHOUT DYNAMIC STEERING - Vehicles with 4-Cylinder TFSI Engine for over views .
In vehicles with 4-Cylinder engines where the bolts on the refrigerant line connection at the A/C compressor are not accessible, remove the A/C compressor from the bracket. Refer to A/C COMPRESSOR, REMOVING AND INSTALLING ON BRACKET .
If the refrigerant line on the low pressure side is to be removed (from the refrigerant line with the inner heat exchanger to the A/C compressor), then the components, which must be removed, depending on the routing of the refrigerant line (routing is dependent on the engine).
-- Remove the bolts -A-.
-- Remove the refrigerant lines -B- and -C-.
All vehicles
Risk of damaging refrigerant lines and hoses.
- Do not stretch, kink or bend refrigerant lines and hoses.
Seal open pipes and connections on the A/C compressor with caps (to prevent dirt and moisture from getting in).