Detaching and re-attaching refrigerant lines from/to expansion valve — AUDI

🧭 Before you start

Fits: Audi A3 (8P, 2003–2012)

• Opens: refrigerant (A/C)

Don't miss

• Seal open lines and the connections at the expansion valve with suitable caps (to prevent the ingress of dirt and moisture).

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Drain the refrigerant circuit Air conditioner with refrigerant R134a87Refrigerant circuit (air conditioner with refrigerant R134a, refrigerant circuit, working with air conditioner service station).
2. Remove the components impeding access to the bolts of the refrigerant lines (A) at the expansion valve. [Note: Depending on the engine and vehicle model, it may be necessary to unfasten or remove the following components: Top engine cover, compressed air pipe to throttle valve unit and intake manifold etc. Engine, mechanics13.On vehicles with 5-cyl. engine, remove the air pipe (from the air cleaner to the turbocharger) Injection and ignition system24.Depending on the engine (e.g. on certain 2.0 l diesel engines depending on the exhaust system design), it may be necessary to remove the plenum chamber cover and the front wall of the plenum chamber (A) in order to be able to remove the heat shield and detach the refrigerant lines from the expansion valve as well as the coolant hoses to the heat exchanger General body repairs, exterior55.There are different versions of the heat shield (B). With version "“1”", the speed nuts (A) have to be removed and the heat shield (B) detached from the vehicle.With version "“2”", the clamping washers (A) and the clip (C) have to be removed and the heat shield (B) detached from the vehicle. If the heat shield (B) is a hindrance to further work (on account of the coolant hoses), separate the heat shield (B) at the location marked (D) (e.g. using side-cutting pliers) and remove the entire shield.For greater clarity, the illustrations show the heat shield (B) with the engine removed.]
3. If fitted, detach the heat shield (B) from the front wall of the plenum chamber and the bulkhead and lay it aside (or remove it completely).
4. Remove the bolts (A) (tightening torque 10 Nm). — 10 Nm (7.4 lb-ft)
5. Detach the refrigerant lines (B) and (C). [Note: Seal open lines and the connections at the expansion valve with suitable caps (to prevent the ingress of dirt and moisture).]
6. Replace the O-rings (D) and (E). For version refer to: Electronic parts catalogue
7. Check the fitted pin (G) (fitted in the connection or expansion valve, not provided with all connections) and the sleeve (H) for damage and proper attachment. [Note: Lubricate O-rings lightly with refrigeration oil before fitting .Pay attention to correct positioning of the O-rings in the groove (F) of the corresponding refrigerant line.Take care not to strain the refrigerant lines on installation.Depending on the vehicle equipment and the engine, the refrigerant lines may be provided with thermal insulation. This must not be damaged and must be re-attached following installation.Check the installation position of the refrigerant lines to the expansion valve (they must not make contact with other components) as well as the position and condition of the thermal insulation which may be attached to the refrigerant lines (not fitted with all types of engine).]

Other AUDI procedures

• Removing and installing toothed belt – Audi · 56 torque figures
• Removing engine – Audi A8 D3 · 41 torque figures
• Removing camshaft timing chain from camshafts – Audi A6/A7 C7 · 38 torque figures
• Installing engine – Audi A8 D4 · 36 torque figures
• Removing and installing camshaft timing chain · 29 torque figures
• Renewing oil seal(left) for input shaft and oil seal for left flange shaft
• Servicing front brakes
• Removing and installing pedal cluster, LHD
• Checking electrolyte level
• Servicing drive shaft with triple roller joint