FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
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Home >> Audi >> 2012 >> S5 Quattro Cabriolet (8F7) V6-3.0L SC (CCBA) >> Repair and Diagnosis >> Heating and Air Conditioning >> Service and Repair >> Removal and Replacement >> Refrigerant Circuit Components >> Refrigerant Lines For Battery Cooling Module In Luggage Compartment

Refrigerant Lines For Battery Cooling Module In Luggage Compartment







Refrigerant Lines for Battery Cooling Module 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.

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.

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

- Turn off the ignition.

- Drain the refrigerant circuit.

- Remove the high voltage battery.

- Remove the bolts - 2, 3 - and remove the refrigerant lines - 1, 4 -.






- Remove the bolts - 2 and 4 - and disconnect and remove the refrigerant pipes - 1 and 3 -.






• Close all open lines and connections on the refrigerant line with suitable caps (avoid dirt and moisture from entering the system).

Installing

Installation is carried out in the reverse order while observing the following.

• Follow the instructions for installing the O-rings. Refer to => [ Refrigerant Circuit O-rings ] Refrigerant Circuit O-Rings.

• Following attachment, check routing of refrigerant pipes. They must be inserted in holders provided and not make contact with other components.

- Replace the O-ring seals - 4 - depending on the version. Refer to Electronic Parts Catalog (ETKA).






- Clean the refrigerant line connections - 3, 5 - and inspect them for damage.

- Make sure the O-ring fits correctly inside the grooves - 4 - on the respective mounts.

- Inspect the alignment pin - 2 - (not present on all connections) for damage and make sure that it is seated correctly.

- Tighten the bolts - 1 -.

- Install the remaining removed components.

- Evacuate and fill the refrigerant circuit.

- 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)

- 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.
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