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Air Conditioning: Removal & Installation Audi A6 C5 facelift

Automatic HVAC System 6 illustrations ~1761 words

Notes for installation

  1. After installing, always carry out On Board Diagnostic (OBD) of air conditioning system. See «ON BOARD DIAGNOSTIC (OBD), INITIATING»(ref-196289-S18205730672005100800000) .
  2. When installing the positioning motor, make sure that the actuator arm is properly engaged.
  3. Install the wiring harness so that it cannot come in contact with any moving parts (e.g. the actuating arm on the positioning motor).

Scheme 2

Scheme 2: Actuator for temperature flap left -V158-, removing and installing
Scheme 2: Actuator for temperature flap left -V158-, removing and installing

Scheme 3

Scheme 3
Scheme 3
  1. Remove storage compartment on driver's side. See «DRIVER'S STORAGE COMPARTMENT, REMOVING»(ref-196285-S31412443952005100800000).
  2. Remove entire center section of instrument panel and also reinforcement bracket. See «INSTRUMENT PANEL»(ref-196286-S17644685922005100800000).
  3. Remove left hand instrument panel support by unscrewing bolt -A-, bolts -B- (2x) and bolts -C- (2x). see scheme 54
  4. Remove wiring harness -D- from left instrument panel support.
  5. Disconnect harness connector -A-. (Scheme 4)
  6. Remove 3 bolts -B-.
  7. Carefully disengage coupling rod -C- using screwdriver -D- and remove positioning motor.
  1. After installing, always carry out On Board Diagnostic (OBD) of air conditioning system. See «ON BOARD DIAGNOSTIC (OBD), INITIATING»(ref-196289-S18205730672005100800000).
  2. When installing the positioning motor, make sure that coupling rod -C- is properly engaged. (Scheme 4)
  3. Install the wiring harness so that it cannot come in contact with any moving parts (for example, the actuating arm on the positioning motor).
  1. After installing, always carry out On Board Diagnostic (OBD) of air conditioning system. See «ON BOARD DIAGNOSTIC (OBD), INITIATING»(ref-196289-S18205730672005100800000).
  2. When installing the positioning motor, make sure that coupling rod -C- is properly engaged. see scheme 56
  3. Install the wiring harness so that it cannot come in contact with any moving parts (for example, the actuating arm on the positioning motor).
  1. After installing, always carry out On Board Diagnostic (OBD) of air conditioning system. See «ON BOARD DIAGNOSTIC (OBD), INITIATING»(ref-196289-S18205730672005100800000).
  2. When installing the positioning motor, make sure that coupling rod -C- is properly engaged. see scheme 57
  3. When installing the positioning motor, make sure that the location pin on the actuating arm engages properly in the can plate.
  4. Install the wiring harness so that it cannot come in contact with any moving parts (for example, the actuating arm on the positioning motor).

Notes on installation

  1. After installing, always perform On Board Diagnostic (OBD) of air conditioning system. See «ON BOARD DIAGNOSTIC (OBD), INITIATING»(ref-196289-S18205730672005100800000).
  2. Install the wiring harness so that it cannot come into contact with any moving parts (e.g. the actuating arm on the positioning motor).
  3. When installing the positioning motor, make sure that locating pins -D- and -E- engage properly in actuating arms -F- and -G-. see scheme 59
  1. After installing, always carry out On Board Diagnostic (OBD) of air conditioning system. See «ON BOARD DIAGNOSTIC (OBD), INITIATING»(ref-196289-S18205730672005100800000).
  2. Install the wiring harness so that it cannot come in contact with any moving parts (e.g. the actuating arm on the positioning motor).
  3. When installing positioning motor, make sure guiding -D- engages properly in lever -E-. see scheme 60

Instrument panel vent removal tool, making

  1. Bend piece of wire (3 mm) as shown.
  2. Measurement x = 12 mm.
  3. Use hammer to angled piece to width y = 2 mm.

Scheme 4

Scheme 4
Scheme 4

A/C system, running after installation of compressor

  1. If a new compressor has been installed or new refrigerant oil has been put into the compressor (for example, after blowing through the A/C system), the compressor must be turned by hand approx. 10 revolutions. This ensures that the compressor is not damaged when activated.
  2. Only start engine after refrigerant circuit has been assembled.
  3. Only start engine with system recharged. NOTE: Different compressors, depending on engine Compressor is always driven (by belt pulley or via drive shaft to engine (it does not have an A/C clutch)
  4. The compressor is equipped with an "internal oil circuit", this prevents compressor damage in the event that the system is empty. A residual amount of refrigerant oil must be in the compressor as a requirement for internal lubrication.
  5. The engine should only be started when the refrigerant circuit is completely and properly installed. For example; if the refrigerant lines are not connected, when the engine is running the compressor may heat up (via internal heat generation) so much that the compressor will be damaged. The A/C Compressor Regulator Valve -N280- is not activated when the system is empty, and the compressor runs at idle with the engine.
  6. The necessary oil to lubricate the compressor is not transferred, since no refrigerant is available.
  7. In order to avoid compressor damage, the compressor is lubricated by an "internal oil circuit". If it is necessary to start the engine with a discharged refrigerant circuit
  8. The refrigerant circuit must be completely assembled.
  9. At least one quarter of designated refrigerant oil for this circuit must be in the compressor.
  10. Engine speed should not increase above 2500 RPM.
  11. The engine should only runs as long as absolutely necessary
  12. Observe the following when starting the engine after recharging the refrigerant circuit: Start engine with compressor switched off ("ECON" mode) and wait until idle speed has stabilized. Open dash panel vents. Select "Lo" on A/C Control Head -E87-. Now switch on compressor ("AUTO" mode) and run for at least 5 minutes with the engine at idle.

Scheme 5

Scheme 5: Removing (compressor drive via a drive shaft)
Scheme 5: Removing (compressor drive via a drive shaft)

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7
  1. Discharge A/C refrigerant system. See «A/C REFRIGERANT SYSTEM (R-134A), DISCHARGING»(ref-196290-S05926919532005100800000).
  2. Support engine using 10-222A engine support bridge (so that left engine mount can be removed).
  3. Remove noise insulation: See «NOISE INSULATION PANEL, ASSEMBLY OVERVIEW»(ref-196278-S12661534982005100800000).
  4. Disconnect refrigerant lines from condenser. See «REFRIGERANT LINES FOR CONDENSER, REMOVING AND INSTALLING»(ref-196290-S29742155002005100800000).
  5. Remove lock carrier completely: See «LOCK CARRIER WITH ATTACHMENTS, REMOVING AND INSTALLING»(ref-196278-S04365420232005100800000).
  6. Unscrew retaining clamp -arrow- for refrigerant line on bracket.
  7. Remove oil dipstick from engine
  8. Remove left engine mount completely (engine console, engine mount and engine support).
  9. Hold compressor drive shaft -A- in place using open-end wrench and turn compressor drive unit -B- in direction of arrow -C-. NOTE: Drive shaft -A- must not be turned. see scheme 145 Drive shaft -A- can be slid into drive wheel through the boot -E- after loosening threaded connection.
  10. Remove bolts -A- (tightening torque 20 Nm). see scheme 146
  11. Detach refrigerant lines from A/C compressor and seal off all open connections. See «REFRIGERANT LINES ON COMPRESSOR, DISCONNECTING AND CONNECTING (COMPRESSOR WITH A/C COMPRESSOR REGULATOR VALVE -N280-)»(ref-196290-S24242294682005100800000).
  12. Disconnect 2-pin harness connector to A/C Compressor Regulator Valve -N280-. NOTE: Do not bend or stretch lines or hoses as condenser and/or refrigerant lines/hoses may be damaged.
  13. Remove bolts -D- (tightening torque 25 Nm). see scheme 146
  14. Remove compressor toward front.
  15. Remove bushings -F- from compressor if necessary.
  1. Before installing, check all gaskets and seals on the air conditioner unit for damage and replace if necessary.
  2. After assembling, all cable ties which were removed in order to take out the air conditioner must be reinstalled in their original positions.
  3. Replace both O-rings for the refrigerant lines.
  4. Make sure refrigerant lines are not under stress when installed.
  5. Make sure that the condensation drainage duct and condensation drain valve are properly seated.

Replace compressor, without it being necessary to blow through the refrigerant system with compressed air and nitrogen (e.g. exterior damage after an accident)

  1. Discharge A/C system. See «A/C REFRIGERANT SYSTEM (R-134A), DISCHARGING»(ref-196290-S05926919532005100800000) .
  2. Remove damaged compressor.
  3. Remove oil drain plug from compressor.
  4. Drain old refrigerant oil out of malfunctioning compressor into a measuring container. Record volume of drained refrigerant oil. NOTE: Rotate compressor manually to speed up oil draining process. The compressor oil drain plug O-ring has been replaced with a sealing ring (always replace).
  5. Drain refrigerant oil also out of replacement compressor into a clean container. Refill replacement compressor with amount of fresh oil equal to the amount poured out of malfunctioning compressor.

Example

From the malfunctioning compressor only 70 cm3 (2.4 oz) of refrigerant oil was poured out. From the replacement compressor 220 cm3 of refrigerant oil poured out (a small amount remains in compressor). 70 cm3 (2.4 oz) of refrigerant oil needs to be poured back into replacement compressor (oil originally from replacement compressor, held in clean container).

Note. If a larger amount of refrigerant oil poured out of the malfunctioning compressor, more than approx. 80 cm3 (2.7 oz) the remaining refrigerant oil can be used for the condenser or accumulator.

  1. Replace restrictor.
  2. Assemble A/C system, evacuate and recharge. See «A/C REFRIGERANT SYSTEM (R-134A), EVACUATING AND RECHARGING»(ref-196290-S41081025962005100800000) .

Replace compressor due to leaks or interior damage (e.g. noises or no power)

  1. Discharge A/C system. See «A/C REFRIGERANT SYSTEM (R-134A), DISCHARGING»(ref-196290-S05926919532005100800000) .
  2. Remove compressor. NOTE: If there is interior damage (to compressor), check refrigerant hoses. If there are chips embedded, replace hose.
  3. Blow through A/C system with compressed air and nitrogen. See «A/C REFRIGERANT SYSTEM (R-134A), FLUSHING WITH COMPRESSED AIR AND NITROGEN»(ref-196290-S15906845982005100800000) .
  4. Replace accumulator and restrictor.
  5. Assemble A/C system, evacuate and charge. See «A/C REFRIGERANT SYSTEM (R-134A), EVACUATING AND RECHARGING»(ref-196290-S41081025962005100800000) .

Replace accumulator and restrictor after blowing through the A/C system e.g. caused by penetrating moisture (the A/C system was open over a long period of time) or contamination (dirt)

  1. Discharge A/C system. See «A/C REFRIGERANT SYSTEM (R-134A), DISCHARGING»(ref-196290-S05926919532005100800000) .
  2. Remove compressor.
  3. Eliminate cause of malfunction.
  4. Blow through A/C system with compressed air and nitrogen. See «A/C REFRIGERANT SYSTEM (R-134A), FLUSHING WITH COMPRESSED AIR AND NITROGEN»(ref-196290-S15906845982005100800000) .
  5. Remove oil drain plug out of compressor.
  6. Drain old refrigerant oil out of compressor into measuring container.
  7. Record volume of refrigerant oil drained. NOTE: Rotate compressor manually to speed up oil draining process. The compressor oil drain plug O-ring has been replaced with a sealing ring (always replace).
  8. Fill compressor with new refrigerant oil: the amount of oil must be equal to amount of old refrigerant oil drained. NOTE: Fill amounts for refrigerant oil. See «A/C REFRIGERANT R-134A AND REFRIGERANT OIL (PAG), CAPACITIES»(ref-196290-S36185935582005100800000) . To ensure adequate compressor lubrication, add at least 80 cm3 (2.7 oz) of refrigerant oil into compressor. The remainder can be added to new accumulator. See «A/C REFRIGERANT R-134A AND REFRIGERANT OIL (PAG), CAPACITIES»(ref-196290-S36185935582005100800000) . If there is dirt in the compressor of an open A/C system (e.g. during an accident), replace compressor.
  9. Blow through A/C circuit with compressed air and nitrogen.
  10. Replace accumulator and restrictor.
  11. Assemble A/C system, evacuate and charge. See «A/C REFRIGERANT SYSTEM (R-134A), EVACUATING AND RECHARGING»(ref-196290-S41081025962005100800000) .

Replace accumulator, without it being necessary to blow through A/C system with compressed air and nitrogen (e.g. damage caused by an accident), no refrigerant flowed out and no moisture and dirt have penetrated the circuit

  1. Discharge A/C system. See «A/C REFRIGERANT SYSTEM (R-134A), DISCHARGING»(ref-196290-S05926919532005100800000) .
  2. Replace restrictor.
  3. Remove accumulator.
  4. Clean accumulator.
  5. Weigh removed accumulator.
  6. Fill new accumulator with new refrigerant oil until it weighs as much as removed accumulator.
  7. Install accumulator.
  8. Assemble A/C system, evacuate and recharge. See «A/C REFRIGERANT SYSTEM (R-134A), EVACUATING AND RECHARGING»(ref-196290-S41081025962005100800000) .

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