Pass-Through Refrigerant Lines In Luggage Compartment
Pass-Through Refrigerant Lines in Luggage Compartment
With high voltage systems (hybrid vehicles)
Read and follow all of the supplemental warnings for all work performed on vehicles with the high voltage system.
If it is necessary for the following procedure to perform work in the vicinity of high voltage components, perform a visual inspection of the high voltage components and cables for damages. Refer to => [ Visual Inspection of High-Voltage Components and Cables for Damage ] Visual Inspection of High-Voltage Components and Cables For Damage and always follow the warnings when working on the high voltage system.
Risk of unintended engine start
The ignition must be turned off and the ignition key must remain outside of the vehicle when working on vehicles with a high voltage system.
How to handle high voltage cable:
• Do not stand on or place tools on high voltage cables and their components as it may damage the cable insulation.
• Never bend or kink high voltage cables forcefully as it may damage the cable insulation.
• Color-code the round high voltage connector with an external color ring and code them mechanically using the guide- or code tabs. Always make certain that the coding matches when connecting the round connector in order to avoid mechanically damaging the high voltage connector.
There is a risk of electrocution from damaged high voltage components
Observe the following when working around high voltage components and high voltage wires:
• Never work around high voltage components and cables with cutting, deformed, or sharp edged tools, or heat sources such as welding or soldering tools, heated air, and thermal glue.
• Inspect the high voltage components visually before beginning.
• Perform a visual inspection of the electric drive power and control electronics (JX1) , the electro-drive drive motor (V141) , the A/C compressor (V470) and the high voltage lines when working in the engine compartment.
• Perform a visual inspection of the high voltage lines and the cover when working on the underbody.
• Perform a visual inspection of the high voltage lines and the Electrobox with the high voltage system maintenance connector (TW) when working in the luggage compartment.
• Perform a visual inspection on all of the potential equalization cables.
Observe the following items when performing the visual inspection:
• The components do not display any signs of external damage.
• The high voltage cable insulation and the potential equalization cables are not damaged.
• The high voltage cables do not display any abnormal deformations.
• Every high voltage component is marked with a red warning label.
The following procedure requires working on the high voltage system. De-energize the high voltage system.
- De-energize the high voltage system.
Disable the high voltage system
Risk of electrocution
Death or serious bodily injury by electric shock.
• People with electric/medical life- and health sustaining devices in or on their person must not perform any work on the high voltage system for safety reasons. Internal pain killer pumps, implanted defibrillators, pacemakers, insulin pumps and hearing aids among others are considered life- and health sustaining devices.
• The high voltage system may only be activated by qualified personnel (Audi high voltage mechanic).
• Make sure that the high voltage system is completely disabled. Assure that the voltage performed exclusively using the Vehicle Diagnosis Tester according to the "Guided Fault Finding".
• The qualified personal (Audi high voltage technician) determines the voltage and secures the system from restarting using the locking cap (T40262). Keep the ignition key and the high voltage system maintenance connector (TW) safely with the qualified personal to secure the system from restarting.
• The qualified personal (Audi high voltage technicians) marks the vehicle by attaching warning labels.
• Disable the high voltage system:
• Connect the vehicle diagnosis tester
• Select the Guided Fault Finding mode
• Using the GO TO button, select the following menu commands
• Functions/Component selection
• Body
• Electrical Equipment
• OBD-capable system
• 8C - Hybrid battery management -J840
• 8C - Hybrid battery management, functions
• 51 - Disable the high voltage system (Rep.Gr. 93)
Removing
- Drain the refrigerant circuit.
- Remove the traction battery.
- Remove the bolts - 2 and 4 - and the refrigerant pipes - 1 and 3 -.
- Remove the bolts - 1, 3 - and disconnect and remove the refrigerant lines - 2, 4 -.
• Close all open lines and connections on the refrigerant line with suitable caps (avoid dirt and moisture from entering the system).
- Remove the nuts - arrows - and remove the pass-through for the refrigerant lines - 1 -.
Installing
Installation is carried out in the reverse order while observing the following.
• If the seal for the pass-through is damaged, seal the seal in this spot with for example, silicone adhesive (D 176 001 A3). Refer to Electronic Parts Catalog (ETKA).
• The adhesive surface must be clean and free of grease when applying the silicone adhesive.
- Install the rear refrigerant lines on the floor panel for the battery cooling module. Refer to => [ Rear Refrigerant Lines to Battery Cooling Module ] Rear Refrigerant Lines to Battery Cooling Module.
- Install the refrigerant lines for the battery cooling module in the luggage compartment. Refer to => [ Refrigerant Lines for Battery Cooling Module in Luggage Compartment ] Refrigerant Lines For Battery Cooling Module In Luggage Compartment.
- Install the remaining removed components.
- Energize the voltage to the high voltage system.
Restart the high voltage system
Risk of electrocution
Death or serious bodily injury by electric shock
• People with electric/medical life- and health sustaining devices in or on their person must not perform any work on the high voltage system for safety reasons. Internal pain killer pumps, implanted defibrillators, pacemakers, insulin pumps and hearing aids among others are considered life- and health sustaining devices.
• The high voltage system may only be restarted by qualified personal (Audi high voltage technicians).
• Assure that the restart is performed exclusively using the Vehicle Diagnosis Tester according to the "Guided Fault Finding".
• The qualified personal (Audi high voltage technician) restarts the vehicle.
• The qualified personal (Audi high voltage technicians) marks the vehicle by attaching warning labels.
• Restart the high voltage system:
• Connect the vehicle diagnosis tester
• Select the Guided Fault Finding mode
• Using the GO TO button, select the following menu commands
• Functions/Component selection
• Body
• Electrical Equipment
• OBD-capable system
• 8C - Hybrid battery management -J840
• 8C - Hybrid battery management, functions
• 51 - High voltage restart (Rep.Gr. 93)
- Evacuate and fill the refrigerant circuit.
- Switch on the ignition.
- Check and, if necessary, erase the displayed faults in the DTC memory for the Climatronic control module (J255) display and control head and the A/C compressor control module (J842). Refer to Vehicle Diagnosis Tester in the Guided Fault Finding Function.
- Operate the A/C system after filling the refrigerant circuit. Refer to => [ A/C System, Operating after Filling Refrigerant Circuit ] A/C System, Operating After Filling Refrigerant Circuit.
• Note the information regarding operating the A/C system after filling.