Leaking Or Damaged Components Except A/C Compressor, Reservoir Or Receiver/Dryer

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The refrigerant circuit was completely empty (for example with larger leak or cracked hose line)

NOTE:

In the event of only a minor leak with slow escape of refrigerant (for example at a small leakage point), the amount of refrigerant oil lost and the amount of moisture penetrating is not sufficient to influence the A/C system function.

The operations marked * are only to be implemented in case of a major leak (for example after a collision).

Electrically-Driven A/C Compressor

-- Remove the faulty component. Refer to Refrigerant Circuit (vehicle-specific Service Information).

-- Remove the electrically-driven A/C compressor and flush. Refer to Refer to ELECTRICALLY-DRIVEN A/C COMPRESSOR, FLUSHING (REMOVING REFRIGERANT OIL) *.

-- Clean the refrigerant circuit (flush with Refrigerant R134a). Refer to Refer to REFRIGERANT CIRCUIT, CLEANING (FLUSHING) WITH REFRIGERANT R134A *.

-- Fill the A/C compressor or the refrigerant circuit completely with refrigerant oil to the specified capacity.

Mechanically Driven A/C Compressor

-- Remove the faulty component. Refer to Refrigerant Circuit (vehicle-specific Service Information).

-- Remove the A/C compressor. Refer to A/C Compressor (1 Of 2) / A/C Compressor (2 Of 2) (vehicle-specific Service Information)*.

-- Remove the oil drain plug -B- / -D- from the A/C compressor -A-.*

Fig 1: Identifying Removal Of Oil Drain Plug -B- / -D- From A/C Compressor -A-

Courtesy of AUDI OF AMERICA, LLC

NOTE:

There are different versions of the oil drain plug -B- / -D- and seal -C- / -E- (depending on the A/C compressor manufacturer).

When installing the oil drain plug -B- / -D-, pay attention to the tightening specification (dependent on the A/C compressor manufacturer and the oil drain plug version). For example, a seal is installed on the oil drain plug on a "Denso" and "Delphi" A/C compressor (tightening specification currently 30 Nm on a "Denso" A/C compressor and 15 Nm on a "Delphi" A/C compressor). On "Sanden" or "Zexel- / Valeo" A/C compressors an oil drain plug or a seal is installed depending on the version on the oil drain plug (tightening specification currently 10 Nm).

A/C compressors made by "Denso" or "Nippondenso" and "Delphi" have an oil drain plug -D-, for example, with a seal -E- installed on it. Replace according to the Parts Information.

Depending on the version, an O-ring or a seal -C- is installed on the oil drain plug -B- on a "Sanden" or "Zexel/ Valeo" A/C compressor. To replace, refer to the Parts Information.

If the seals (seal or O-ring) that are installed on the oil drain plug are not available as a replacement part, the removed seals may be used as an exception (check for damage before installing). If the removed seal is damaged or deformed if necessary replace with a commercially available component.

To accelerate drainage of refrigerant oil, rotate the A/C compressor by way of clutch plate of A/C clutch, for example.

After charging the refrigerant circuit check the installed oil drain plug for leaks for example using an electronic leak detector.

Drain the old refrigerant oil from the A/C compressor* (Disposing. Refer to Audi-ServiceNet, HSO Environment).

All

NOTE:

Then fill A/C compressor with quantity of fresh refrigerant oil corresponding to quantity of refrigerant oil in replacement A/C compressor. Refer to Refer to APPROVED REFRIGERANT OILS AND REFRIGERANT OIL CAPACITIES .*

Use different refrigerant oils and quantities for the various A/C compressors. Refer to Refer to APPROVED REFRIGERANT OILS AND REFRIGERANT OIL CAPACITIES .

To ensure compressor lubrication on start-up, at least 40 cm³ of refrigerant oil must be poured into the compressor. The remainder can be added to the new reservoir or receiver/dryer. Refer to Refer to APPROVED REFRIGERANT OILS AND REFRIGERANT OIL CAPACITIES .

If dirt has penetrated into the compressor with the refrigerant circuit open (for example after an accident), compressor is to be replaced.

Clean refrigerant circuit (flush with refrigerant R134a (Refer to REFRIGERANT CIRCUIT, CLEANING (FLUSHING) WITH REFRIGERANT R134A .) or blow through with compressed air and nitrogen (Refer to Refer to REFRIGERANT CIRCUIT, CLEANING WITH COMPRESSED AIR AND NITROGEN .)*

-- Replace the dryer cartridge*, receiver/dryer* or reservoir* and restrictor. Refer to Refrigerant Circuit (vehicle-specific Service Information).

-- Assemble, evacuate and recharge the refrigerant circuit.

Refrigerant circuit still contains refrigerant (for example, with minor leak)

-- Discharge the refrigerant circuit.

-- Remove the malfunctioning component, flush with compressed air, collect escaping refrigerant oil.

-- The new component is to be filled with the amount of refrigerant oil flushed out (positive 20 cm³ for evaporator, positive 10 cm³ for condenser, refrigerant pipes and refrigerant hoses) as fresh refrigerant oil fill.

NOTE:

Dispose of old refrigerant oil (pay attention to local regulations). Refer to VW / Audi ServiceNet.

-- If equipped, replace the restrictor. Refer to Refrigerant Circuit (vehicle-specific Service Information).

-- Assemble, evacuate and charge the refrigerant circuit.