Expansion Valve, Removing And Installing: 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 A/C SYSTEM, GENERAL INFORMATION (Refrigerant R134a, Servicing; A/C System General Information).
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.
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 .
-- 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 refrigerant line with inner heat exchanger. Refer to REFRIGERANT LINES WITH INNER HEAT EXCHANGER, REMOVING AND INSTALLING .
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
-- Disconnect the ground connection from the Battery -A-. Refer to BATTERY, DISCONNECTING AND CONNECTING .
-- Remove the plenum chamber cover and/or the cowl panel trim (different versions). Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .
Vehicles with a 6-Cylinder TDI engine:
-- Remove the refrigerant line with inner heat exchanger. Refer to REFRIGERANT LINES WITH INNER HEAT EXCHANGER, REMOVING AND INSTALLING .
All vehicles except vehicles with a 6-Cylinder TDI engine:
-- Loosen the refrigerant line with inner heat exchanger from the expansion valve and vehicle and lay it to the side (do not remove). Refer to REFRIGERANT LINES WITH INNER HEAT EXCHANGER, REMOVING AND INSTALLING .
On vehicles with the 6-Cylinder TDI engine, the shape of the front wall of the plenum chamber does not leave enough space to move the refrigerant line to the side.
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).
When loosening the plenum chamber front wall, be careful not to damage the brake booster vacuum line.
All vehicles
-- Remove the bolts -A-.
-- Disconnect the expansion valve -B- from the refrigerant lines leading to the evaporator.
Seal all open lines and connections on evaporator with suitable caps (avoid dirt and moisture from entering the system).