RS5
Refrigerant Pipe with Inner Heat Exchanger
Special tools, testers and auxiliary items required
• Engine bung set (VAS 6122)
• Release tool for air conditioner couplings (T40149) or removal tool (T40232)
Removing
- Turn off the ignition.
- Drain the refrigerant circuit.
- Remove the nut - 6 - and open the clamp - 5 -.
- Remove the refrigerant pipe - 2 - from the quick-release connection - 1 -. Refer to => [ Refrigerant Lines Disconnecting from Quick-Release Couplings and Connecting ] Refrigerant Lines Disconnecting From Quick-Release Couplings and Connecting.
- Remove the bolt - 3 - and disconnect the refrigerant line - 4 -.
- Seal open lines and connections with clean bungs from engine bung set (VAS 6122).
- Remove the plenum chamber cover and/or the cowl panel (there are different versions).
- Disconnect the ground cable from the battery (A).
- Disengage the catches - arrows A - and remove the upper part of the line pass-through - 2 - upward - arrow B -.
- Loosen the wiring harness - 1 - from the lower part of the wire pass-through and then remove the lower part.
- Loosen the plenum chamber front all - A - from the vehicle.
- Remove screws - 1 -.
- Disconnect the refrigerant line - 2 - with the inner heat exchanger from the expansion valve.
- Seal open lines and connections with clean bungs from engine bung set (VAS 6122).
Installing
Installation is done is reverse order, observe the following:
- Thoroughly clean all the connections in the expansion valve - B - and in the refrigerant line - D - with the inner heat exchanger.
- Check the connections in the expansion valve - B - and on the refrigerant line - D - for damage.
- Replace the quick-coupling connection on the refrigerant line with inner heat exchanger. Refer to=> [ Refrigerant Lines Disconnecting from Quick-Release Couplings and Connecting ] Refrigerant Lines Disconnecting From Quick-Release Couplings and Connecting.
- Replace the O-rings - A - and - C -. 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.
- Make sure the O-rings fit properly inside the grooves on the refrigerant line connections - D -.
- Tighten the bolts - E - for the refrigerant line - D - with inner heat exchanger.
• Tightening specification - E -: 10 Nm.
• On certain versions, the refrigerant pipe with an inner heater core - A - also have a weight (balance) - B - to reduce noise. When installing the refrigerant pipes with an inner heater core and the plenum chamber bulkhead, make sure the weight and the refrigerant pipe are not too close to the other components or touching them.
- Clean the connections on the refrigerant pipe and check for damage.
- Inspect the alignment pin - 4 - for damage and check that it is seated correctly.
- Inspect the guide ring - 2 - on the refrigerant line connection for damage.
• Coat the O-ring with refrigerant oil before installing. Refer to => [ Refrigerant Circuit O-rings ] Refrigerant Circuit O-Rings.
• Make sure the O-ring fits correctly inside the groove in the refrigerant pipe.
- Insert the O-ring seal - 3 - in the groove - arrow - on the refrigerant line connection - 1 -.
- The cover - 1 - must sit correctly on the refrigerant pipe - 2 - as illustrated.
- Make sure the rubber bushing - 4 - is seated in the mount.
- Install the refrigerant pipe - 6 - on the inner heat exchanger and tighten the bolt - 5 -.
• Tightening specification: 9 Nm.
- Attach the refrigerant pipe - 3 - to the quick-coupling connection. Refer to => [ Refrigerant Lines Disconnecting from Quick-Release Couplings and Connecting ] Refrigerant Lines Disconnecting From Quick-Release Couplings and Connecting.
• Install refrigerant line such that it is not strained.
• Check installation position of refrigerant line to expansion valve (it should not come in contact with other components).
- Install the remaining removed components.
- Evacuate and fill the refrigerant circuit.
- 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.
- Switch on the ignition.
- Check the DTC memory and erase any displayed entries. Refer to the Vehicle diagnostic tester in "Guided Fault Finding".