Removing and installing refrigerant lines in plenum chamber — AUDI

🧭 Before you start

Fits: Audi A4 B9 (8W, 2015–)

• Opens: refrigerant (A/C)

Don't miss

• Danger from the escape of pressurised refrigerant.Frostbite on the skin and other parts of the body.Always drain the refrigerant circuit before slackening off the bolts at the connection points. — Switch off the ignition.
• Seal open line connections at the connection point with clean plugs for example from the engine bung setVAS 6122.
• Moisten the O-rings slightly with refrigeration oil before fitting Refrigerant circuit seals.
• Make sure that the support ring (G) is correctly positioned and check the grommet in the back wall of the plenum chamber for damage and proper installation.
• Take care not to strain the refrigerant lines on installation.

📋 Procedure

1. ⚠ Danger from the escape of pressurised refrigerant.Frostbite on the skin and other parts of the body.Always drain the refrigerant circuit before slackening off the bolts at the connection points. — Switch off the ignition.
2. Drain the refrigerant circuit Air conditioner with refrigerant R134a87Refrigerant circuit.
3. Remove the plenum chamber cover General body repairs, exterior50Bulkhead; Removing and installing plenum chamber cover. [Note: The plenum chamber cover must be intact to stop water running into the heater and air conditioning unit via the intake housing with the plenum chamber cover fitted. The plenum chamber cover must also be properly and fully engaged in the windscreen frame General body repairs, exterior50Bulkhead; Removing and installing plenum chamber cover.]
4. Unfasten the plenum chamber bulkhead from the vehicle and lay aside (do not remove) General body repairs, exterior50Bulkhead; Exploded view - bulkhead.
5. To remove the refrigerant line (C), take out the windscreen wiper motor Electrical system92Windscreen washer system; Removing and installing windscreen wiper motorV.

6. Unscrew the nut (D), tightening torque Exploded view - components beneath wing and in plenum chamber.
7. Unfasten the service connections (B, F) of the two refrigerant lines to the expansion valve from the holder (A) and detach from the internal heat exchanger (E). [Note: Seal open line connections at the connection point with clean plugs for example from the engine bung setVAS 6122.]
8. Unscrew the nut (A), tightening torque Exploded view - components beneath wing and in plenum chamber.
9. Detach both refrigerant lines (B, C) from the expansion valve (D) at the front. Detaching refrigerant lines from front expansion valve/re-attaching [Note: Seal open line connections at the connection point with clean plugs for example from the engine bung setVAS 6122.]
10. Remove the refrigerant line (B).
11. Remove the refrigerant lines (C) in the direction of the left wing (beneath the brake servo).
12. Replace all O-rings ((E, F) in this illustration); different versions Electronic parts catalogue. [Note: Moisten the O-rings slightly with refrigeration oil before fitting Refrigerant circuit seals.]
13. Thoroughly clean the expansion valve, penetration and refrigerant lines in the connection area and check for damage.
14. Make sure that the support ring (G) is correctly positioned and check the grommet in the back wall of the plenum chamber for damage and proper installation.
15. Replace all O-rings ((E, G) in this illustration); different versions Electronic parts catalogue. [Note: Moisten the O-rings slightly with refrigeration oil before fitting Refrigerant circuit seals.]
16. Insert the two refrigerant lines (C, D) to the expansion valve and the service connections (B, H) in the holder following attachment to the internal heat exchanger (F).
17. Tighten the nut (A). [Note: Take care not to strain the refrigerant lines on installation.]
18. Following attachment, check the routing of the refrigerant lines. Ensure strain-free insertion in the holders provided and make sure the lines do not come into contact with other components.
19. Re-install the components removed in reverse order/re-attach the components unfastened.
20. Evacuate and charge the refrigerant circuit Air conditioner with refrigerant R134a87Refrigerant circuit.
21. Switch on the ignition.
22. Interrogate the event memory of the front air conditioner operating and display unit E87 and erase any faults displayed "“Guided fault-finding”" mode.
23. Start up the air conditioner after charging the refrigerant circuit . [Note: Also heed the information on start-up of the air conditioner after charging Air conditioner with refrigerant R134a87General information on air conditioner.]

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