2009 Audi Q5 Service & Repair Manual

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG. Repair Manual Audi Q5 2008 ➤ Heating, Ventilation and Air Conditioning Edition 12.2008 Service Service Department. Technical Information

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG. List of Workshop Manual Repair Groups Repair Group 87 - Air Conditioning Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. Service All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2008 Audi AG, Ingolstadt A005Q502021

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG. Contents 87 - Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.2 General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.3 A/C System Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.4 Contact Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.5 A/C Components Controlled or Activated by Other Control Modules . . . . . . . . . . . . . . . . . . 4 1.6 Refrigerant Circuit, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.7 Refrigerant Circuit Discharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.8 Working on Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.9 Refrigerant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.10 Painting Vehicles with A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.11 Refrigerant Circuit O-ring Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.12 Air Quality Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.13 A/C System Control and Regulation Components Outside Passenger Compartment . . . . 12 1.14 A/C System Control and Regulation Components Inside Passenger Compartment . . . . . . 13 1.15 Dust and Pollen Filter with Activated Charcoal Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1.16 Climatronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 1.17 Glove Compartment Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 1.18 A/C Unit and Air Intake Housing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 1.19 A/C Air Intake and Outlet Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 1.20 Air Conditioner, Levers and Connecting Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 1.21 A/C System, Operating after Filling Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1.22 Evaporator, Cleaning with Ultrasonic HVAC Cleaning System VAS 6189 . . . . . . . . . . . . . . 22 2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 2.1 A/C System Components Outside Passenger Compartment Overview . . . . . . . . . . . . . . . . 25 2.2 A/C System Components Inside Passenger Compartment Overview . . . . . . . . . . . . . . . . 34 2.3 A/C Unit and Air Intake Housing Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 2.4 A/C Unit and Air Intake Housing Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 2.5 A/C Control Motor Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 2.6 Air Routing and Distribution Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 2.7 Air Routing in Air Intake Housing and A/C Unit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 53 2.8 A/C Unit Air Intake and Outlet Openings Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 2.9 Radiator Housing Temperature Door Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 2.10 Air Distributor Housing Doors and Partitions Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 2.11 Refrigerant Circuit Component Overview, Charged A/C System . . . . . . . . . . . . . . . . . . . . 63 2.12 Refrigerant Circuit Component Overview, Discharged A/C System . . . . . . . . . . . . . . . . . . 66 2.13 A/C Compressor Pulley Component Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 3.1 Fastener Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 4 Diagnosis and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 4.1 Checking Components Actuated by A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 4.2 A/C Pressure/Temperature Sensor, Checking Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 4.3 A/C Pressure and Temperature Sensor, Checking Pressure Signal . . . . . . . . . . . . . . . . . . 81 4.4 A/C Compressor Regulator Valve, Checking Activation Signal . . . . . . . . . . . . . . . . . . . . . . 82 4.5 A/C Compressor Regulator Valve, Electrical Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 4.6 Air Quality Sensor, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 4.7 A/C Cooling Output, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 4.8 Heat Output and Temperature Door Activation, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 102 5 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 5.1 Instrument Panel and Rear Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 5.2 Sunlight Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Audi Q5 2008 ➤ Heating, Ventilation and Air Conditioning - Edition 12.2008 Contents i

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG. 5.3 Dust and Pollen Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 5.4 Condensation Water Drain Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 5.5 Passenger Compartment Forced Air Extraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 5.6 Plenum Chamber Water Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 5.7 Fresh Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 5.8 A/C Pressure/Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 5.9 Outside Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 5.10 Air Quality Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 5.11 A/C Compressor Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 5.12 Climatronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 5.13 Interior Temperature Sensor Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 5.14 A/C Unit Air Intake Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 5.15 Right Footwell Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 5.16 Left Footwell Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 5.17 Air Intake Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 5.18 Fresh Air Blower Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 5.19 Fresh Air Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 5.20 Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 5.21 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 5.22 Left Radiator Housing with Temperature Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 5.23 Right Radiator Housing with Temperature Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 5.24 A/C Unit Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 5.25 Refrigerant Line Quick Release Couplings, Disconnecting and Connecting . . . . . . . . . . . . 204 5.26 Refrigerant Lines with Inner Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 5.27 Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 5.28 Refrigerant Lines to Condenser, Disconnecting and Connecting . . . . . . . . . . . . . . . . . . . . 212 5.29 Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 5.30 Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 5.31 Evaporator, A/C Unit Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 5.32 A/C Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227 5.33 Refrigerant Lines to Compressor, Disconnecting and Connecting . . . . . . . . . . . . . . . . . . . . 236 5.34 A/C Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 6 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 6.1 A/C Unit Air Intake Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 6.2 Evaporator Housing Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247 6.3 Retaining Plate with Footwell Door Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 6.4 A/C Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251 6.5 Retaining Plate with Right Footwell Door Motor and Center Vent Motor . . . . . . . . . . . . . . 255 6.6 Retaining Plate with Left Footwell Door Motor and Center Vent Motor . . . . . . . . . . . . . . . . 256 6.7 A/C Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 7 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 Audi Q5 2008 ➤ Heating, Ventilation and Air Conditioning - Edition 12.2008 ii Contents

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG. 87 – Air Conditioning 1 General Information ⇒ “1.1 Safety Precautions”, page 1 ⇒ “1.2 General Repair Information ”, page 2 ⇒ “1.3 A/C System Additional Information”, page 3 ⇒ “1.4 Contact Corrosion”, page 3 ⇒ “1.5 A/C Components Controlled or Activated by Other Control Modules”, page 4 ⇒ “1.6 Refrigerant Circuit, Servicing”, page 5 ⇒ “1.7 Refrigerant Circuit Discharging”, page 5 ⇒ “1.8 Working on Refrigerant Circuit”, page 6 ⇒ “1.9 Refrigerant Capacities”, page 7 ⇒ “1.10 Painting Vehicles with A/C System”, page 8 ⇒ “1.11 Refrigerant Circuit O-ring Seals”, page 8 ⇒ “1.12 Air Quality Sensor”, page 9 ⇒ “1.13 A/C System Control and Regulation Components Outside Passenger Compartment”, page 12 ⇒ “1.14 A/C System Control and Regulation Components Inside Passenger Compartment”, page 13 ⇒ “1.15 Dust and Pollen Filter with Activated Charcoal Insert”, page 14 ⇒ “1.16 Climatronic Control Module”, page 16 ⇒ “1.17 Glove Compartment Cooling”, page 18 ⇒ “1.18 A/C Unit and Air Intake Housing Components”, page 19 ⇒ “1.19 A/C Air Intake and Outlet Routing”, page 20 ⇒ “1.20 Air Conditioner, Levers and Connecting Elements”, page 20 ⇒ “1.21 A/C System, Operating after Filling Refrigerant Circuit”, page 21 ⇒ “1.22 Evaporator, Cleaning with Ultrasonic HVAC Cleaning System VAS 6189”, page 22 1.1 Safety Precautions The following safety measures should be observed for this refrig‐ erant system (additional guidelines apply in individual countries). If is necessary to open the refrigerant circuit during service work, discharge the refrigerant circuit first, refer to ⇒ “1.7 Refrigerant Circuit Discharging”, page 5 . In doing so, the utmost care is to be taken to avoid contact with the liquid re‐ frigerant or refrigerant vapors. Should refrigerant nevertheless escape, avoid inhaling the resultant refrigerant/air mixture. Extraction systems are therefore to be switched on and use safety equipment consisting of both rubber gloves and protective gog‐ gles. Audi Q5 2008 ➤ Heating, Ventilation and Air Conditioning - Edition 12.2008 1. General Information 1

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG. Reason Intensive exposure to refrigerant on unprotected parts of the body will result in frostbite. WARNING Keep an eye bath on hand. If liquid refrigerant has come in contact with your skin and eyes, immediately flush with cool water for 15 minutes. Then apply eye drops and consult a doctor immediately even if no pain is felt. The doctor must be informed, which type of refrigerant caused the freezing. Should refrigerant come into contact with other parts of the body despite compliance with all the pertinent safety measures, these are similarly to be rinsed thoroughly in cold water without delay for at least 15 minutes. Although refrigerant does not represent a fire hazard, smoking, welding, soldering and brazing are not permitted in areas exposed to refrigerant. Reason The high temperature of a naked flame or hot objects causes de‐ composition of refrigerant gas. Inhalation of the resultant toxic decomposition products leads to dry coughing and nausea. 1.2 General Repair Information WARNING Before working on the electrical system (wiring), remove rele‐ vant fuse(s) Note Disconnect the battery before starting electrical work on vehicle. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Removal and Installation . The Air Conditioning (A/C) refrigerant system may be discharged and opened only if it is for safety reasons, refer to ⇒ “1.3 A/C System Additional Information”, page 3 , or if com‐ ponents of the A/C refrigerant system must be replaced, refer to ⇒ “1.7 Refrigerant Circuit Discharging”, page 5 . When performing all other usual vehicle repair work, the refriger‐ ant circuit of the A/C system should remain closed. Repairs to the heating and A/C without opening the refrigerant circuit are possible and are described in this repair manual, refer to ⇒ “2.11 Refrigerant Circuit Component Overview, Charged A/C System”, page 63 , ⇒ “1.13 A/C System Control and Regulation Components Outside Passenger Compartment”, page 12 and ⇒ “1.14 A/C System Control and Regulation Components Inside Passenger Compartment”, page 13 . Audi Q5 2008 ➤ Heating, Ventilation and Air Conditioning - Edition 12.2008 2 Rep. Gr.87 - Air Conditioning

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG. Note The connections for the sensors/switches described in this repair manual are fitted with a valve which closes automatically when the sensor/switch is removed. These sensors/switches can thus be replaced in any Audi workshop even though the refrigerant circuit is fully charged. Service work on the A/C system that require the refrigerant circuit to be discharged and thus cannot be performed in every Audi workshop is described in ⇒ “1.6 Refrigerant Circuit, Servicing”, page 5 . Certain tools are required to discharge the refrigerant circuit, these work pro‐ cedures must only be performed by trained personnel as well. Therefore, bring the vehicle to a workshop that has the necessary tools and in which the work can be performed accordingly by qualified personnel if necessary. Refer to ⇒ Refrigerant R134a - Servicing . ♦ Contact corrosion, refer to ⇒ “1.4 Contact Corrosion”, page 3 . ♦ A/C components controlled or activated by other control mod‐ ules, refer to ⇒ “1.5 A/C Components Controlled or Activated by Other Con‐ trol Modules”, page 4 . ♦ Components actuated by A/C system, refer to ⇒ “4.1 Checking Components Actuated by A/C System”, page 74 . 1.3 A/C System Additional Information The assemblies and piping system of the air conditioner are filled with the following refrigerant: 1.1.1.2 Tetrafluorethane (CF 3 -CH 2 F or CH 2 F-CF 3 ) Currently, this refrigerant is known under the following trade names R134a, H-FKW 134a, SUVA 134a and KLEA 134a (other trade names may be used in other countries). Appropriate current flow diagrams can be found in current flow diagrams, electrical fault finding and fitting locations. Refer to ⇒ Wiring diagrams, Troubleshooting & Component locations. A data plate in the engine compartment indicates the refrigerant used and capacity. Additional notes for repair work on vehicles with Air Conditioning (A/C) system and for handling refrigerant can be found in ⇒ Re‐ frigerant R134a - Servicing . 1.4 Contact Corrosion Contact corrosion can occur if inappropriate fasteners (bolts, nuts, washers, rivets, plugs, grommets, adhesives etc.) are used. For this reason, the manufacturer only installs fasteners with a special surface coating. Also, rubber and plastic parts and adhe‐ sive consist of materials that do not conduct electricity. These parts, which have been tested and are aluminum compatible, are also available as replacement parts. Refer to ⇒ Electronic Parts Catalog . Note ♦ Always install new parts if there is any doubt as to whether parts can be reused. Audi Q5 2008 ➤ Heating, Ventilation and Air Conditioning - Edition 12.2008 1. General Information 3

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG. ♦ Original equipment replacement parts are recommended. They have been test and are compatible with aluminum, refer to ⇒ Electronic Parts Catalog . ♦ Audi accessories are recommended, refer to ⇒ Electronic Parts Catalog . ♦ Damage due to contact corrosion is not covered by warranty. 1.5 A/C Components Controlled or Activa‐ ted by Other Control Modules Note ♦ Different Air Conditioning (A/C) components are not controlled directly by the A/C control head climatronic control head - J255- . For example the A/C compressor regulator valve - N280- is controlled by the vehicle electrical system control module -J519- . The data is exchanged via the data bus sys‐ tem between both control modules. Refer to ⇒ Vehicle Diag‐ nosis, Testing and Information System VAS 5051 in "Guided Fault Finding" function. . ♦ The measured values of the different A/C components are not evaluated directly by the A/C control head climatronic control head -J255- . For example, the pressure signal from the A/C pressure/temperature sensor -G395- is evaluated from the ve‐ hicle electrical system control module -J519- and the meas‐ ured values are sent via the data bus system to the A/C control head climatronic control unit -J255- . Refer to ⇒ Vehicle Di‐ agnosis, Testing and Information System VAS 5051 in "Gui‐ ded Fault Finding" function ⇒ Wiring diagrams, Troubleshoot‐ ing & Component locations. Audi Q5 2008 ➤ Heating, Ventilation and Air Conditioning - Edition 12.2008 4 Rep. Gr.87 - Air Conditioning

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG. 1.6 Refrigerant Circuit, Servicing Note ♦ No refrigerant must be added into the refrigerant circuit . Refer to ⇒ Refrigerant R134a - Servicing . ♦ Compressor is always driven when engine is running; there is no magnetic clutch. Engine is therefore not to be started un‐ less refrigerant circuit has been properly assembled. If for example the refrigerant lines are not connected to the com‐ pressor and the engine is started then the compressor may be destroyed by the buildup of internal heat. Such internal heat generation results from the fact that , even with delivery ap‐ proaching 0%, the compressor is confronted with a fixed re‐ sistance (sealed circuit). ♦ To stop the compressor from being destroyed when the re‐ frigerant circuit is empty, it is designed such that delivery is reduced to roughly 0% and lubrication is maintained by way of an internal oil circuit with the oil left in the compressor. ♦ The entire amount of refrigerant oil to be added to the refrig‐ erant circuit is in the replacement compressor. Refer to ⇒ Refrigerant R134a - Servicing . ♦ Different refrigerant oils are required for compressors made by Denso, Sanden and Zexel/Valeo. Refer to ⇒ Refrigerant R134a - Servicing and ⇒ Electronic Parts Catalog . ♦ Coat O-ring seals lightly with refrigerant oil before installing. Refer to ⇒ “1.11 Refrigerant Circuit O-ring Seals”, page 8 . ♦ The specified diameters for O-rings seals and the tightening specifications pertain also to the threaded connections of the refrigerant lines or refrigerant hoses between the separate components. ♦ Only install O-rings seals that are approved for Refrigerant R134a, refer to ⇒ “1.11 Refrigerant Circuit O-ring Seals”, page 8 , ⇒ Re‐ frigerant R134a - Servicing and ⇒ Electronic Parts Catalog . ♦ Check cooling performance, refer to ⇒ “4.7 A/C Cooling Output, Checking”, page 92 . ♦ Check pressures in refrigerant circuit, refer to ⇒ Refrigerant R134a - Servicing . ♦ All refrigerant circuit servicing and test procedures not descri‐ bed in this repair manual, refer to ⇒ Refrigerant R134a - Servicing ♦ Operate the A/C system after filling the refrigerant circuit, refer to ⇒ “1.21 A/C System, Operating after Filling Refrigerant Cir‐ cuit”, page 21 . ♦ Refrigerant circuit, servicing. Refer to ⇒ “2.12 Refrigerant Circuit Component Overview, Discharged A/C System”, page 66 . 1.7 Refrigerant Circuit Discharging The refrigerant must be discharged using an air conditioning service station and should not be released into the environment. The discharged refrigerant will be locally recycled or is send to an environment-recycling place to the manufacturer (different or ad‐ ditional laws may apply in individual companies). For this reason, bring vehicle to a workshop that has the necessary tools and in Audi Q5 2008 ➤ Heating, Ventilation and Air Conditioning - Edition 12.2008 1. General Information 5

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG. which the work can be performed accordingly by qualified per‐ sonnel. Refer to ⇒ Refrigerant R134a - Servicing . Reason If refrigerant R134a is released into the environment, it enhances the green house effect. Note ♦ Refrigerant R134a has far less of a greenhouse effect than R12. ♦ Because R134a does not contain chlorine atoms, the major catalyst in ozone depletion, refrigerant R134a has no ozone depletion potential. Depletion of the ozone layer in the upper atmosphere is however only brought about by the splitting of carbon chlorine bonds (as is the case, for example, with re‐ frigerant R12). Disconnect the connector from the Air Conditioning (A/C) com‐ pressor regulator valve -N280- or from the A/C pressure/temper‐ ature sensor -G395- after draining the air conditioner. Reason A/C compressor regulator valve -N280- is then no longer activa‐ ted and compressor runs at idle. Compressor is designed such that lubrication of compressor components is guaranteed by way of an internal oil circuit at idle (provided there is sufficient refrig‐ erant oil in the compressor). 1.8 Working on Refrigerant Circuit Work on refrigerant system should only be performed in a venti‐ lated room (workshop). Ensure that within a 5 meter circumfer‐ ence are no work pits, basement staircases or shafts. Extraction systems are to be switched on. Reason The refrigerant emerging is not only colorless and odorless, but also heavier than air and thus displaces oxygen. If refrigerant gas does escape even though all the safety precautions have been followed, there is a risk of suffocating in poorly ventilated areas and in workshop pits - even if it is not noticeable. Note The escaping refrigerant/air mixture should not be inhaled, but should be sucked out via an existing exhaust ventilation system. Do not attempt repair on filled air conditioning systems by solder‐ ing, brazing or welding. This pertains also for welding and sol‐ dering work on the vehicle, in the event that parts of the climate control system may heat up. Reason Exposure to heat creates considerable pressure in the system, which could cause it to burst. Corrective Action Discharge refrigerant circuit. Refer to ⇒ “1.7 Refrigerant Circuit Discharging”, page 5 . Audi Q5 2008 ➤ Heating, Ventilation and Air Conditioning - Edition 12.2008 6 Rep. Gr.87 - Air Conditioning

2009 Audi Q5 Service & Repair Manual

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