4-Cylinder Engine
Electric A/C Compressor
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 work near high voltage components, perform a visual inspection of the high voltage components and cables for damage, refer to => [ Visual Inspection of High-Voltage Components and Cables for Damage ] Visual Inspection of High-Voltage Components and Cables For Damage and High Voltage System General Warnings.
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.
It is necessary to work on the high voltage system for the following procedure. High voltage system, de-energizing.
- Switch off the ignition.
- 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 de-energized using the Vehicle diagnostic tester in "Guided Fault Finding".
• The qualified person (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 person to secure the system from restarting.
• The Audi high voltage technician should put a sign on the vehicle to identify it as a high voltage vehicle.
• 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.
• Depending on the allocation of the service connection an 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.
- Remove the engine cover - arrows -.
- Free up the attaching points - 1 - and - 3 - for the high voltage system cable on the engine - 2 - and electric wiring harness - 4 -.
Unlock and disconnect the high voltage system connector - 3 - on the A/C compressor.
• Do not bend the high voltage cable.
• Only remove the connector horizontally from the connection after releasing it. Never turn the connector.
- Pull the locking mechanism in the - direction of the arrow -.
- Remove the connector from the A/C compressor horizontally, and without turning.
- Cover the high voltage cable connector and socket on the A/C compressor (such as with a clean plug from the engine bung set (VAS 6122) ) to protect them from debris and damage.
- Disconnect the connector - 2 - (for low voltage on the A/C compressor).
• Ignore - 1 and 4 -.
- Remove the refrigerant lines from A/C compressor. Refer to => [ A/C Compressor Refrigerant Lines ] A/C Compressor Refrigerant Lines.
- Removing the A/C compressor from the bracket. Refer to => [ Electric A/C Compressor Removing from Bracket ] Electric A/C Compressor Removing From Bracket.
Installing
Installation is carried out in the reverse order while noting the following:
Before installing the A/C compressor refer to A/C Service Station
• There is an unspecified amount of refrigerant oil in the removed compressor so follow the information on replacing the compressor.
- Attach the A/C compressor to the bracket. Refer to => [ Electric A/C Compressor Removing from Bracket ] Electric A/C Compressor Removing From Bracket.
- Install the A/C compressor refrigerant pipes. Refer to => [ A/C Compressor Refrigerant Lines ] A/C Compressor Refrigerant Lines.
• Coat the O-ring seals lightly with refrigerant oil prior to installation. Refer to => [ Refrigerant Circuit O-rings ] Refrigerant Circuit O-Rings.
• After the installation of the electric A/C compressor and the subsequent filling of the refrigerant circuit, start up the A/C compressor for the first time using the "compressor intake" function for the basic setting. The A/C compressor may otherwise become damaged if before installation, refrigerant oil was improperly stored in the A/C compressor compression chamber. Refer to the Vehicle diagnostic tester in "Guided Fault Finding" Function for A/C System and Battery Regulator.
• Only activate the electric A/C compressor when the refrigerant circuits is filled. Damage to the A/C compressor may occur if the A/C compressor is running while the refrigerant circuit is empty. Refer to the Vehicle diagnostic tester in "Guided Fault Finding" Function for A/C System and Battery Regulator.
- Evacuate and fill the refrigerant circuit.
- Insert and secure the electrical connection for the high voltage system on the A/C compressor.
• Do not bend the high voltage cable.
• Only insert the connector in the designated position (connector coding) on the A/C compressor. Never turn the connector.
- Inspect the connector for debris and damage.
- Plug the connector into the A/C compressor.
• The marks - 1 - and - 2 - on the connector and A/C compressor must line up with each other.
- Secure the locking mechanism in the - direction of the arrow -.
- Install the remaining removed parts in the opposite order.
- De-energize the voltage supply 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)
- 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 electric A/C compressor (V470) using the function "Compressor Cut-In". Refer to the Vehicle diagnostic tester in "Guided Fault Finding" Function for A/C System and Battery Regulator.
- 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.