Removing and installing refrigerant lines with internal heat exchanger - Audi Q5 hybrid — AUDI

🧭 Before you start

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
• Also covered elsewhere: Electronic parts catalogue

Don't miss

• Use e.g. clean sealing plugs (B) (size 20) from engine bung setVAS 6122 for covering connections at JX1(A)
• Seal open lines and connections at refrigerant line with suitable caps (to prevent ingress of dirt and moisture).
• Disregard (item 1).
• Seal open connections at refrigerant line and expansion valve with suitable caps (to prevent ingress of dirt and moisture).
• Observe fitting instructions for O-rings .

📋 Procedure

1. Switch off ignition.
2. 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 (e.g. on the Audi Q5) Running gear, axles, steering40Suspension strut, upper links; Exploded view - suspension strut, upper links and Air conditioner with refrigerant R134a87General notes on air conditioning systems.] [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. — Remove rubber seal (A) and plenum chamber cover (B) (different versions) General body repairs, exterior50Bulkhead; Removing and installing plenum chamber cover.
4. De-energise high-voltage system Electrical system93De-energising high-voltage system.
5. Detach earth connection from batteryAElectrical system27Battery; Disconnecting and connecting battery.

6. Remove rubber seal (A) and plenum chamber cover (B) (different versions) General body repairs, exterior50Bulkhead; Removing and installing plenum chamber cover.
7. Detach earth connection from batteryAElectrical system27Battery; Disconnecting and connecting battery.
8. Unfasten power distributor (1) and set it down together with wiring towards windscreen Electrical system97Relay carriers, fuse carriers, electronics boxes; Overview of fitting locations - relay carriers, fuse carriers, electronics boxes.
9. Detach high-voltage wiring to JX1Electrical system93High-voltage wires; Overview of fitting locations - high-voltage wires.
10. Cover JX1 and corresponding wiring to prevent damage or contamination Electrical system93General warning instructions for work on the high-voltage system. [Note: Use e.g. clean sealing plugs (B) (size 20) from engine bung setVAS 6122 for covering connections at JX1(A)] [Note: Should it be necessary in order to be able to remove and install the refrigerant line with internal heat exchanger, remove the cowl panel trim (C)General body repairs, exterior50Bulkhead; Removing and installing plenum chamber cover.From model year 2010 onwards, certain vehicle versions are fitted with refrigerant lines with internal heat exchanger (A) with an additional weight (damper) (B) to reduce noise (depending on the engine). When installing the refrigerant lines with internal heat exchanger (A) and the plenum chamber partition panel, make sure that the weight (B) and the refrigerant lines (A) are not too close to or do not make contact with other components.]
11. Detach refrigerant line from quick-release couplings . [Note: Seal open lines and connections at refrigerant line with suitable caps (to prevent ingress of dirt and moisture).]
12. Unfasten plenum chamber partition panel (A) from vehicle General body repairs, exterior50Bulkhead; Exploded view - bulkhead. [Note: On vehicles with a petrol engine or 4-cyl. TDI engine, the two coolant hoses to the heat exchanger are routed through the plenum chamber partition panel (A). On these vehicles, detach grommet at both coolant hoses and move partition panel to one side (this avoids having to open the coolant circuit).When unfastening the plenum chamber partition panel, pay attention to the vacuum line to the brake servo to avoid damaging it.]
13. Release fasteners (arrows A) and lift off top section of pipe gland (2)(arrow B). [Note: Disregard (item 1).]
14. Unfasten wiring harness from bottom section of pipe leadthrough (2) and remove bottom section.
15. Unscrew nut (C) at suspension turret.
16. Remove bolts (A).
17. Detach refrigerant line (B) with internal heat exchanger from expansion valve. [Note: Seal open connections at refrigerant line and expansion valve with suitable caps (to prevent ingress of dirt and moisture).] [Note: For electrical connections and routing, refer to .]
18. Thoroughly clean all connections in expansion valve (B) and in refrigerant line (D) with internal heat exchanger.
19. Check connections in expansion valve (B) and at refrigerant line (D) for damage.
20. Renew quick-release couplings at refrigerant line with internal heat exchanger .
21. Renew O-rings (A) and (C); for correct version, refer to Electronic parts catalogue. [Note: Observe fitting instructions for O-rings .]
22. Lubricate O-rings lightly with refrigerant oil before installing .
23. Make sure that O-rings are correctly positioned in grooves of refrigerant line connections at refrigerant line (D).
24. Tighten bolts (E) for refrigerant line (D) with internal heat exchanger.
25. Tighten nut (C) for refrigerant line (B).
26. Install plenum chamber partition panel General body repairs, exterior50Bulkhead; Exploded view - bulkhead. [Note: Take care not to strain refrigerant line during installation.Check installation position of refrigerant line to expansion valve (it must not make contact with other components).]
27. Attach refrigerant line to quick-release couplings .
28. Re-install remaining components (removed earlier).
29. 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).
30. For electrical connections and routing, refer to .
31. 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)]
32. ⚠ 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.
33. 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").
34. 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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