Get Connecting air conditioner service station Guide for Audi A2 SUV 1999-2005

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A1 Sportback 2 ...

Air conditioner with refrigerant R134a - Edition 11.2018

7

Connecting air conditioner service

station

Vehicles with high-voltage system (hybrid vehicles)

High voltage! Danger to life!

The voltage levels in the high-voltage system constitute a safety

hazard. Danger of severe or fatal injuries from electric shock.

– Persons with life-sustaining or other electronic medical devi‐

ces in or on their body must not perform any work on the high-

voltage system. Such medical devices include internal anal‐

gesic pumps, implanted defibrillators, pacemakers, insulin

pumps and hearing aids.

– The high-voltage system must be de-energised by a suitably

qualified person.

Risk of injury - engine may start unexpectedly

It is difficult to determine whether the drive system of an electric

vehicle or hybrid vehicle is active. Moving parts can trap or draw

in parts of the body.

– Switch off ignition.

– Place ignition key outside vehicle.

Risk of damage to high-voltage wiring

Incorrect handling may result in damage to the insulation of high-

voltage wires or high-voltage connectors.

– Never use high-voltage wiring or high-voltage connectors as

a support.

– Never prop tools against high-voltage wiring or high-voltage

connectors.

– Never bend or kink high-voltage wiring.

– Pay attention to coding when connecting high-voltage con‐

nections.

♦ For all work on vehicles with high-voltage system, note addi‐

tional warnings for working on such vehicles

⇒ “1 Warning instructions when working on vehicles with high-

voltage system”, page 1 .

♦ If work near high-voltage system components is necessary,

perform a visual check of the high-voltage components and

wires to check for damage ⇒ page 2 .

♦ If work on high-voltage system components is necessary, de-

energise high-voltage system ⇒ Rep. gr. 93 ; De-energising

high-voltage system or ⇒ Electrical system; Rep. gr. 93 ; De-

energising high-voltage system .

7. Connecting air conditioner service station

187

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A1 Sportback 2 ...

Air conditioner with refrigerant R134a - Edition 11.2018

Note

When working on the refrigerant circuit using the air conditioner

service station, the high-voltage system does not usually have to

be de-energised.

– To minimise the number of automatic engine starts when the

vehicle's drive system is active during test and measurement

work, charge the vehicle batteries e.g. with the battery

charger 60A - VAS 5904- in battery standby mode ⇒ Electrical

system; General information; Rep. gr. 27 ; Battery; Charging

battery and ⇒ Electrical system; Rep. gr. 93 ; General warning

instructions for work on the high-voltage system .

– For test and measurement work that requires the vehicle's

drive system to be active (READY) or the ignition to be switch‐

ed on, move the selector lever to position “P”, activate the

parking brake and take care to keep well clear of the engine

when it is running. Set up any tools needed so that they cannot

come into contact with moving parts.

Note

♦ Move the selector lever to position “P” and activate the parking

brake before performing test and measurement work for which

the ignition must be switched on but where the vehicle's drive

system does not need to be active.

♦ The status of the drive system (READY) is shown by the con‐

trol unit in dash panel insert - J285- via the “power meter” ⇒

Owner's Manual .

♦ Activating and deactivating drive system ⇒ Owner's Manual

(note display of control unit in dash panel insert - J285- ).

Vehicles with start/stop system

Risk of injury - engine may start unexpectedly

The engine can start unexpectedly if the vehicle's start/stop sys‐

tem is activated. A message in the instrument cluster indicates

whether the start/stop system is activated.

– To deactivate the start/stop system, switch off the ignition.

All vehicles

– Switch off ignition.

188

Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A1 Sportback 2 ...

Air conditioner with refrigerant R134a - Edition 11.2018

⇒ “7.1 Connecting air conditioner service station - vehicles with a

connection on the low-pressure and high-pressure side of the re‐

frigerant circuit”, page 189

⇒ “7.2 Connecting air conditioner service station - vehicles with

no connection on the low-pressure side of the refrigerant circuit”,

page 190

7.1

Connecting air conditioner service sta‐

tion - vehicles with a connection on the

low-pressure and high-pressure side of

the refrigerant circuit

Connecting air conditioner service station for measuring and test‐

ing

– Switch off ignition.

– Connect air conditioner service station to power supply.

– Connect quick-release coupling adapter to filler hoses of air

conditioner service station (handwheels not screwed in/hand

shut-off valve not open).

– Switch on the air conditioner service station and evacuate the

filler hoses (only necessary if there is air in the filler hoses).

– Switch on air conditioner service station.

– Unscrew sealing caps from service connections (with valve).

– Connect air conditioner service station to vehicle refrigerant

circuit via service connections with quick-release coupling

adapters.

– Only screw in the handwheel of the quick-release coupling

adapters to the extent required to reliably open the valves at

the refrigerant circuit connection (observe pressure gauge, do

not open valves further than necessary).

On vehicles with high-voltage system and additional air condi‐

tioner functions (e.g. on the Audi Q7 e-tron):

Note

On vehicles with the “heat pump” and/or “high-voltage battery

cooling” function, high pressure is not available at the service

connection on the high-pressure side in all air conditioner oper‐

ating modes. On these vehicles, the pressure in the refrigerant

circuit on the high-pressure side can only be measured via the

pressure/temperature senders installed in the refrigerant circuit

(depending on the air conditioner operating mode) ⇒ Heating, air

conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific

Workshop Manual) and ⇒ Vehicle diagnostic tester (“Guided Fault

Finding”).

To check the various functions of these air conditioners:

– On the vehicle diagnostic tester, select the corresponding

function (“passenger compartment cooling”, “heat pump op‐

eration” or “high-voltage battery cooling”) and perform the

function according to requirements ⇒ Vehicle diagnostic tester

in “Guided Fault Finding” mode.

– On the vehicle diagnostic tester, select and read out the meas‐

urements from the various pressure/temperature senders in‐

stalled in the refrigerant circuit ⇒ Vehicle diagnostic tester in

“Guided Fault Finding” mode.

7. Connecting air conditioner service station

189

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A1 Sportback 2 ...

Air conditioner with refrigerant R134a - Edition 11.2018

All vehicles

– Perform planned tests and measurements.

7.2

Connecting air conditioner service sta‐

tion - vehicles with no connection on the

low-pressure side of the refrigerant cir‐

cuit

On the following vehicles, no service connection is provided for

the air conditioner service station on the low-pressure side of the

refrigerant circuit. Adapters are required for connecting the air

conditioner service station to the refrigerant circuit of these vehi‐

cles.

♦ Audi 80, Audi Cabriolet, Audi Coupé

♦ Audi A4 up to 07/96

♦ Audi 100 / Audi A6 up to 03/97

♦ Audi A8 up to 11/97

Note

On vehicles without a connection or with an inaccessible connec‐

tion at the air conditioner compressor, remove the low pressure

switch for air conditioning system - F73- (bridge contacts in con‐

nector for low pressure switch for air conditioning system - F73- )

and screw adapter onto this connection ⇒ Heating, air condition‐

ing; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific Workshop

Manual).

Note

♦ The tools listed below are commercially available or can be

obtained from the regional sales centre or importer.

♦ Should it be necessary to measure pressures at switch con‐

nections on high-pressure side, use adapter from adapter set

for refrigerant circuit - V.A.G 1785/9- and proceed in the same

manner.

190

Rep. gr.87 - Air conditioning system

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A1 Sportback 2 ...

Air conditioner with refrigerant R134a - Edition 11.2018

⇒ “7.2.1 Connecting air conditioner service station to refrigerant

circuit with adapter set for refrigerant circuit V.A.G 1786 ”,

page 191

⇒ “7.2.2 Connecting air conditioner service station to refrigerant

circuit with adapter V.A.G 1785/10”, page 191

⇒ “7.2.3 Connecting air conditioner service station for measuring

and testing”, page 192

7.2.1

Connecting air conditioner service sta‐

tion to refrigerant circuit with adapter set

for refrigerant circuit - V.A.G 1786-

A - Connection with valve (small valve core) at low-pressure side

of refrigerant circuit

B - Adapter with union nut - V.A.G 1786/1-

C - Commercially available filler hose (short version with 5/8"

thread on each end)

D - Adapter with service connection - V.A.G 1786/2- (for connec‐

tion of quick-release coupling of air conditioner service station

-E-)

Note

♦ Assemble adapter and filler hose as shown and start by con‐

necting to connection with valve -A-.

♦ The adapter with union nut - V.A.G 1786/1- is only to be used

at connections with a “small” valve core (standard for connec‐

tion with valve for low-pressure switch for air conditioning

system - F73- and also gradually introduced as of 10.94 at the

air conditioner compressor).

♦ Instead of adapter with union nut - V.A.G 1786/1- , you can

also use adapter - V.A.G 1785/10- (remove valve from adapter

- V.A.G 1785/10- or install valve opener in filler hose).

7.2.2

Connecting air conditioner service sta‐

tion to refrigerant circuit with adapter

V.A.G 1785/10

– Unscrew the sealing cap from the connection with valve -A-

(at the air conditioner compressor).

– Attach O-ring -B- to connection (8.9 mm; 1.8 mm).

– Screw adapter V.A.G 1785/10 -C- onto connection -B-.

– Install valve opener -D- with appropriate seal in filler hose

connection.

Note

♦ The type of valve opener -D- and seals required depends on

the filler hose used (specific to manufacturer).

♦ The quick-release coupling adapter is not required for con‐

nection on the low-pressure side of Audi vehicles.

♦ Screw filler hose -E- (to air conditioner service station) onto

adapter - V.A.G 1785/10- .

7. Connecting air conditioner service station

191

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A1 Sportback 2 ...

Air conditioner with refrigerant R134a - Edition 11.2018

Note

To minimise the amount of air and moisture entering the filler ho‐

ses and thus into the refrigerant circuit, the filler hoses should be

connected as illustrated.

A - Filler hose to air conditioner service station

B - Hand shut-off valve

C - Filler hose (short version) with valve opener for connection to

adapter -D-

D - Adapter - V.A.G 1785/10-

E - Filler hose (short version) with quick-release coupling adapter

(for vehicles with quick-release coupling adapter on low-pressure

side)

– Perform planned tests and measurements.

7.2.3

Connecting air conditioner service sta‐

tion for measuring and testing

– On vehicles with high-voltage system, switch off (deactivate)

auxiliary air conditioner function ⇒ Owner's Manual and ⇒

Infotainment/MMI Operating Manual .

– Switch off ignition.

– Connect air conditioner service station to power supply.

– Assemble adapter set and screw onto connection on low-

pressure side.

– Connect quick-release coupling adapter to filler hoses of air

conditioner service station (handwheels not screwed in/hand

shut-off valve not open).

– Switch on air conditioner service station and evacuate filler

hoses (only necessary if there is air in the filler hoses).

– Switch off air conditioner service station.

– Unscrew the sealing cap from the service connection or the

connection with valve (or remove the low-pressure switch and

jumper the corresponding electrical connections).

– Connect air conditioner service station to vehicle refrigerant

circuit via service connections with quick-release coupling

adapters.

– Only screw in the handwheel of the quick-release coupling

adapters to the extent required to reliably open the valve at the

refrigerant circuit connection (observe pressure gauge, do not

open valve too far).

– Perform planned tests and measurements.

192

Rep. gr.87 - Air conditioning system

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Connecting air conditioner service station for Your Audi A2 SUV 1999-2005

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