Removing and installing air conditioner compressor (electrically driven) - vehicles with 4-cyl. engine — AUDI

🧭 Before you start

Inspect the high-voltage components and have the system de-energised by a qualified technician via the diagnostic tester. Remove the engine cover, free the HV cable, unplug the HV connector horizontally and cap both halves, unplug the low-voltage connector and detach the refrigerant lines, then unbolt the compressor. Install, evacuate and charge the circuit, reconnect and lock the HV plug, re-energise, clear the J255 event memory and run the Compressor run-in function.

Fits: Audi A5 (8T, 2007–2016), Audi Q5 (8R, 2008–2017), Audi A5 Cabriolet (8F), Audi A4 B8 (8K, 2007–2015); platform code 83

• Opens: refrigerant (A/C)
• Special tools named: VAS 5051

Don't miss

• De-energising and re-energising the high-voltage system is for a qualified high-voltage technician using the diagnostic tester only.
• Unplug the HV connector held horizontally and never turn it; cover both halves with clean plugs.
• Do not bend high-voltage wiring and use no cutting tools or heat near it.
• The compressor holds an unknown amount of oil; follow the compressor renewal notes for oil quantity.
• Never run the electric compressor with an empty refrigerant circuit; use Compressor run-in after charging.

Written for this job from the workshop steps below · TorqFix editorial.

📋 Procedure

1. ⚠ Risk of fatal injury if high-voltage components are damaged.Observe the following when working in the vicinity of high-voltage components or wiring:It is not permitted to use cutting or forming tools, other sharp-edged tools or heat sources such as welding, brazing, soldering, hot air or thermal bonding equipment.Before starting work, visually inspect the high-voltage components in the areas involved.Before working in the engine compartment, visually inspect the power and control electronics for electric driveJX1, electric drive motor V141, air conditioner compressor V470 and high-voltage wiring. Before working on the vehicle underbody, visually inspect the high-voltage wiring and covers. Before working on the rear section of the vehicle, visually inspect the high-voltage wiring and the electro-box with the maintenance connector for high-voltage system TW . Visually inspect all potential equalisation lines.Check the following when making the visual inspection:There must be no external damage on any component. The insulation of the high-voltage wiring and potential equalisation lines must not be damaged. There must be no unusual deformation of the high-voltage wiring. All high-voltage components must be identified by a red warning sticker. — Switch off ignition.
2. De-energise high-voltage system Electrical system93De-energising high-voltage system. [Note: De-energising high-voltage system:Connect vehicle diagnostic testerSelect Guided Fault Finding modeUsing the Go to key, select the following menu items in successionFunction/component selectionBodyElectrical systemSelf-diagnosis compatible systems8C - Hybrid battery management -J8408C - Hybrid battery management, functions51 - De-energise high-voltage system (Rep. gr. 93)]
3. ⚠ High voltage can cause fatal injury.Danger of severe or fatal injuries from electric shock. The high-voltage system may only be de-energised by a suitably qualified person (Audi high-voltage technician). It must be definitely confirmed that the high-voltage system is de-energised. The system may only be de-energised using the vehicle diagnostic tester via "“Guided Fault Finding”". The qualified person (Audi high-voltage technician) confirms that the system is de-energised and uses the locking cap T40262 to ensure that the system cannot be re-energised. The ignition key and the maintenance connector for high-voltage system TW should then be stored in a safe place by the qualified person.The qualified person (Audi high-voltage technician) marks the vehicle by attaching the appropriate warning signs. — Discharge refrigerant circuit Air conditioner with refrigerant R134a87Refrigerant circuit (Air conditioner with refrigerant R134a; Refrigerant circuit; Working with the air conditioner service station). [Note: Depending on the position of the service connection at the refrigerant line and the vehicle version, it may be necessary to remove the additional reinforcement for the body brace (left-side) to make it possible to connect the service coupling of the air conditioner service station Running gear, axles, steering40Suspension strut, upper links; Exploded view - suspension strut, upper links and Air conditioner with refrigerant R134a87Refrigerant circuit (Air conditioner with refrigerant R134a; Refrigerant circuit; Working with the air conditioner service station).]
4. Detach engine cover panel (arrows)10Engine cover panel; Removing and installing engine cover panel.
5. Move clear attachment points (1) and (3) of high-voltage system cable at engine (2) and wiring harness (4).

6. ⚠ Take care not to bend high-voltage wires.After releasing the connector, make sure it is horizontal when unplugging it. Do NOT turn the connector. — Pull locking element in direction of (arrow).
7. Unplug connector from air conditioner compressor; connector must be horizontal and must not be turned.
8. Cover high-voltage cable connector and mating plug at air conditioner compressor to prevent damage and contamination (e.g. with clean plugs from engine bung setVAS 6122).
9. Unplug electrical connector (2) (for low voltage on air conditioner compressor). [Note: (Items 1, 4) can be ignored.]
10. Detach refrigerant lines from air conditioner compressor .
11. Detach air conditioner compressor from bracket . [Note: When it is removed, the air conditioner compressor contains an indeterminate amount of refrigerant oil. For this reason it is important to observe the notes on renewing the compressor Air conditioner with refrigerant R134a87Renewing components of refrigerant circuit.]
12. Attach air conditioner compressor to bracket .
13. Attach refrigerant lines to air conditioner compressor . [Note: Lubricate O-rings lightly with refrigerant oil before fitting .After installing the electrically driven compressor and then charging the refrigerant circuit, first start up the compressor by way of the "“Compressor run-in”" function of the basic setting routine. Otherwise, the air conditioner compressor may be damaged if refrigerant oil has accumulated in the compression chamber of the air conditioner compressor due to inappropriate storage prior to installation. Vehicle diagnostic tester in "“Guided Fault Finding”" mode for air conditioner and battery regulationAn electrically driven compressor may only be activated when the refrigerant circuit is charged. Running the air conditioner compressor with the refrigerant circuit empty could lead to compressor damage Vehicle diagnostic tester in "“Guided Fault Finding”" mode for air conditioner and battery regulation.]
14. Evacuate and charge refrigerant circuit Air conditioner with refrigerant R134a87Refrigerant circuit (Air conditioner with refrigerant R134a; Refrigerant circuit; Working with the air conditioner service station).
15. Plug in and lock high-voltage system connector at air conditioner compressor.
16. ⚠ Take care not to bend high-voltage wires.Always plug the connector in at the air conditioner compressor in the specified position (connector coding). Do NOT turn the connector. — Check connector for dirt and damage.
17. Plug in connector at air conditioner compressor.
18. Fasten locking element in direction of (arrow).
19. Re-install remaining components removed in reverse order.
20. Re-energise power supply of high-voltage system Electrical system93De-energising high-voltage system. [Note: Re-energising high-voltage system:Connect vehicle diagnostic testerSelect Guided Fault Finding modeUsing the Go to key, select the following menu items in successionFunction/component selectionBodyElectrical systemSelf-diagnosis compatible systems8C - Hybrid battery management -J8408C - Hybrid battery management, functions51 - Re-energise high-voltage system (Rep. gr. 93)]
21. ⚠ High voltage can cause fatal injury. Danger of severe or fatal injuries from electric shock. The high-voltage system may only be re-energised by a suitably qualified person (Audi high-voltage technician). The system may only be re-energised using the vehicle diagnostic tester via "“Guided Fault Finding”". The vehicle is then made ready for operation again by the qualified person (Audi high-voltage technician).The qualified person (Audi high-voltage technician) marks the vehicle by attaching the appropriate warning signs. — Switch on ignition.
22. Interrogate event memory of operating and display unit (Climatronic control unit J255) and erase any faults displayed Vehicle diagnostic, testing and information system VAS 5051 ("Guided Fault Finding").
23. Start up electrical air conditioner compressor V470 via "“Compressor run-in”" function Vehicle diagnostic tester in "“Guided Fault Finding”" mode for air conditioner and battery regulation.
24. Start up air conditioner after charging refrigerant circuit . [Note: Also observe notes on starting up air conditioner after charging Air conditioner with refrigerant R134a87General notes on air conditioning systems (before using air conditioner after system has been re-charged).]

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