Refrigerant Lines Disconnecting From Quick-Release Couplings and Connecting
Refrigerant Lines Disconnecting from Quick-Release Couplings and Connecting
Special tools, testers and auxiliary items required
• Release tool for the refrigerant lines (T40149)
• Removal tool (T40232) (if the connections cannot be unlocked with (T40149) )
Removing
- Turn off the ignition.
- Drain the refrigerant circuit.
• Depending on the allocation of the service connection and on the refrigerant line, and on the version of the vehicle, it may be necessary to remove the additional reinforcement on the left suspension strut dome so that the service coupling of the service station can be connected (for example, on the Audi Q5).
• There are different quick-release coupling versions - A - and - D -. The refrigerant lines - C - can unlocked and removed using the release tool (T40149/1) in the same manner with both versions.
• The check pins on the - B -quick-release couplings - A - installed at Start Of Production are visible after installing the refrigerant line - C -, when the locked refrigerant line - C - is pulled in the direction of arrow.
• Beginning with MY 2010, as a running change, the quick-release coupling - D - installed and the refrigerant line - C - are being installed in the same manner as the quick-release coupling - A -. If the refrigerant line - C - is pulled in the direction of arrow after assembling, the ring - E - will come out of the quick-release coupling - D - and will show that the retaining ring - F - is completely latched to the refrigerant line - C -. Then the ring - E - can be removed from the refrigerant line - C -.
• If it is not possible to unlock the quick-couplings - A - and - B - using (T40149) without damaging them, then unlock them - A - and - B - using disassembling tool (T40232) - C - three times on the circumference and loosen the ring - D - on the quick-couplings - A - and - B - and the refrigerant pipes - E - and - F -. Remove the refrigerant pipes - E - and - F - from the quick-couplings - A - and - B -.
- Clean the refrigerant lines - A - and - C - in the area of the quick acting coupling connectors.
- Clean the refrigerant lines - A - and - C - in the area of the quick acting coupling connectors with a silicone-free lubricant.
• The refrigerant lines adhere to the O-ring with the A/C is used; loosen the O-ring before mounting the release tool for air conditioner couplings, for example by pulling and pushing the refrigerant lines; never twist the refrigerant lines.
• The Audi RS 4 and the Audi RS 5 have a block connector instead of quick-release connector. Removing and installing the block connector is same as removing and installing the block connector on the condenser. Refer to All except RS5 => [ Refrigerant Pipes from Condenser ] Refrigerant Pipes From Condenser or RS5=> [ Refrigerant Pipes from Condenser ] Refrigerant Pipes From Condenser.
- Press the refrigerant lines - A - and - C - by hand all way into the connecting piece - B - of the refrigerant line with the inner heat exchanger.
- Connect the Release Tool for Air Conditioner Couplings (T40149/1) to the refrigerant line - A - all the way (you should hear and feel the mounting ring open), when doing this, the retaining with will expand.
- Remove the refrigerant line - A - using the release tool for air conditioner coupling from the connector piece - B - of the refrigerant line with inner heat exchanger.
- Connect the Release Tool for Air Conditioner Couplings (T40149/2) to the refrigerant line - C - all the way (you should hear and feel the mounting ring open), when doing this, the retaining with will expand.
- Remove the refrigerant line - C - using the release tool for air conditioner coupling from the connector piece - B - of the refrigerant line with inner heat exchanger.
• If the refrigerant lines cannot be pulled out or pushed in, then never twist them in the connector piece - C -.
• In this case, open (or cut) the quick-couplings - A - or - B - with the disassembly tool (T40232) and remove the ring - D -.
• When cutting the coupling, make sure not to damage the connector piece - A - of the refrigerant line with inner heat exchanger.
Close all open lines and connections on the refrigerant line with suitable caps (avoid dirt and moisture from entering the system).
Loosen the connection on the quick-coupling connections using the disassembly tool (T40232).
- Mount the disassembly tool - C - on the quick-couplings - A - or - B - and separate the coupling 3 times.
• Be careful not to damage the connection on the inner heat exchanger - G - and the refrigerant pipes - E - and - F - when separating the quick-coupling - A - and - B -.
• Insert the cutter on the disassembly tool - C - into the quick-coupling until it audibly breaks the cut location.
- Carefully bend open the cut quick-coupling - A - or - B - (being careful not to damage the refrigerant pipe) and remove the ring - D -.
- Spray the refrigerant pipes near the opened quick-coupling with a silicone-free lubricant.
• The refrigerant pipes stick to the O-ring when the A/C is working. Pulling and pushing the refrigerant pipe after spraying the lubricant can loosen the pipe from the O-ring making it easier to remove. Never rotate refrigerant pipes.
- Remove the refrigerant pipe - E - and - F - from the connection.
- Seal off the open pipes and connections on the refrigerant pipe with caps to keep dirt and humidity from getting in.
Installing
Installation is done is reverse order, observe the following:
Danger of leakage.
• The couplings - B - and - C - on the refrigerant line - D - with inner heat exchanger must be replaced each time the refrigerant line is opened.
- Pry the couplings - B - and - C - using a screwdriver - A - out of the refrigerant line - D - with inner heat exchanger - arrow -.
- Thoroughly clean all parts of the refrigerant line connections (for example, using Cleaning Solution (D 009 401 04) ).
- Check the connector - A - for the refrigerant line with inner heat exchanger for damage.
- Replace the O-rings - B and G -, the support rings - C and F - and the couplings - D and E -. Refer to Electronic Parts Catalog (ETKA).
• Follow the instructions for installing the O-rings. Refer to => [ Refrigerant Circuit O-rings ] Refrigerant Circuit O-Rings.
- Coat the O-ring seals with refrigerant oil prior to installation. Refer to => [ Refrigerant Circuit O-rings ] Refrigerant Circuit O-Rings.
- Press on the couplings - D - and - E - until this audibly latch into the refrigerant line with inner heat exchanger connector piece - A -.
- Thoroughly clean the refrigerant lines - A - and - B - around the connection area and check for damage.
- Install the refrigerant lines - A - and - B - all the way so that they are free of tension.
Check for correct installation of the refrigerant lines.
• Try to disconnect the refrigerant lines - A - and - B - ; the stop must be felt.
• The pins - B - on the retaining ring must be visible on the quick-release coupling, version - A - (installed at Start Of Production) when the locked refrigerant line - C - is pulled in direction of arrow.
• On the quick-release coupling - D - (running change from MY 2010), the ring - E - must come out of the quick-release coupling - D -, when, after assembling, the locked refrigerant line - C - is pulled in direction of arrow. Then the ring - E - can be removed from the refrigerant line - C -.
• Install refrigerant pipes such that they are not strained.
• Check installation position of refrigerant lines to the quick acting couplings (they should not come in contact with other components).
- Evacuate and fill the refrigerant circuit.
- Switch on the ignition.
- Install the remaining removed components.
- Switch on the ignition.
- Check the Climatronic control module (J255) DTC memory and erase any displayed malfunctions if necessary. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".
- 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.