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General information on air conditioning systems -> Basic rules for working on refrigerant circuit for Your 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  
danger of air conditioner components becoming hot. When per‐  
forming paintwork repairs, the temperature in the drying booth or  
preheating zone must not exceed 80 °C.  
Reason:  
Exposure to heat generates considerable pressure in the system,  
which could cause the high-pressure safety valve to open.  
Remedy:  
– Discharge refrigerant circuit using air conditioner service sta‐  
tion.  
Note  
Damaged or leaking components of the air conditioning system  
must not be repaired by welding or soldering. They must always  
be renewed.  
Refrigerant vessels (e.g. charging cylinders of air conditioner  
service station) must never be subjected to excessive heat or ex‐  
posed to direct sunlight.  
Remedy:  
– Vessels must never be completely filled with liquid refrigerant.  
Without sufficient room for expansion (gas cushion), vessels  
will rupture with explosive effect in the event of an increase in  
temperature ⇒ page 11 .  
Refrigerant must NOT be transferred to systems or containers in  
which air is present.  
Remedy:  
– Evacuate systems and containers before charging with refrig‐  
erant.  
2.16  
Basic rules for working on refrigerant cir‐  
cuit  
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.  
22  
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  
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 additional  
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, per‐  
form 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-en‐  
ergise high-voltage system ⇒ Rep. gr. 93 ; De-energising high-  
voltage system .  
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  
♦ General notes ⇒ page 24  
♦ Cleaning refrigerant circuit ⇒ page 24  
♦ Additionally for vehicles with air conditioner compressor with  
no magnetic clutch (with air conditioner compressor regulating  
valve - N280- ) ⇒ page 25  
♦ O-rings ⇒ page 27  
2. General information on air conditioning systems  
23  
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A1 Sportback 2 ...  
Air conditioner with refrigerant R134a - Edition 11.2018  
⇒ “2.16.1 General notes”, page 24  
⇒ “2.16.2 Cleaning refrigerant circuit”, page 24  
⇒ “2.16.3 Additionally for vehicles with air conditioner compressor  
without magnetic clutch (with air conditioner compressor regulat‐  
ing valve N280 only)”, page 25  
⇒ “2.16.4 Additional information on vehicles with high-voltage  
system”, page 25  
⇒ “2.16.5 O-rings”, page 27  
2.16.1  
General notes  
Observe specific instructions relating to workplaces ⇒ Audi  
ServiceNet, HSO Environmental Protection .  
Ensure absolute cleanliness when working.  
Wear safety goggles and gloves when working with refrigerant  
and nitrogen.  
Switch on the available workshop exhaust extraction systems.  
Always use air conditioner service station to discharge refrig‐  
erant circuit, then unfasten screw connections and renew  
defective components.  
Use caps to seal off opened components and hoses to prevent  
moisture and dirt from entering the system.  
Use only tools and materials intended for refrigerant R134a.  
Seal opened refrigerant oil containers to guard against mois‐  
ture.  
Note  
After completing service work, screw sealing caps (with seals)  
onto service connections and all connections with valves.  
Before starting up air conditioning system, check specified ca‐  
pacity for vehicle ⇒ page 292 .  
Do not top up refrigerant in circuit; discharge existing refriger‐  
ant and re-charge system.  
2.16.2  
Cleaning refrigerant circuit  
The refrigerant circuit must be cleaned (flushed) with refrigerant  
R134a ⇒ page 100 (or blown out with compressed air and nitro‐  
gen ⇒ page 95 ) in the following cases:  
– If moisture or dirt has entered the refrigerant circuit (e.g. fol‐  
lowing an accident)  
– If the refrigerant oil is dark and viscous  
– If there is too much refrigerant oil in the refrigerant circuit after  
renewing compressor  
– If the air conditioner compressor has to be renewed due to  
“internal” damage (e.g. noise or no output)  
Note  
When blowing out components with compressed air and nitrogen,  
always extract the gas mixture escaping from the components  
with suitable extraction units (workshop extraction system).  
24  
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  
2.16.3  
Additionally for vehicles with air condi‐  
tioner compressor without magnetic  
clutch (with air conditioner compressor  
regulating valve - N280- only)  
Only start the engine after the refrigerant circuit has been as‐  
sembled completely (constant air conditioner compressor op‐  
eration).  
If the engine has to be operated with the refrigerant circuit  
empty, only do so for as long as absolutely essential and avoid  
increased engine speeds.  
2.16.4  
Additional information on vehicles with  
high-voltage system  
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 if  
high-voltage components or high-voltage wiring are damaged.  
– Carry out visual check of high-voltage components and high-  
voltage wiring.  
– Never use cutting/forming tools or other sharp-edged imple‐  
ments.  
– Never perform work using welding, brazing, thermal bonding  
or hot air.  
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  
2. General information on air conditioning systems  
25  
Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A1 Sportback 2 ...  
Air conditioner with refrigerant R134a - Edition 11.2018  
⇒ “1 Warning instructions when working on vehicles with high-  
voltage system”, page 1 .  
♦ If work is necessary in the vicinity of high-voltage system com‐  
ponents, perform a visual inspection of the high-voltage com‐  
ponents and wiring to check for damage ⇒ page 2 and note ⇒  
Rep. gr. 00 ; Safety precautions or ⇒ Electrical system; Rep.  
gr. 93 ; General warning instructions for work on the high-  
voltage system .  
♦ For further information on the high-voltage system, refer to ⇒  
Rep. gr. 00 ; Safety precautions or ⇒ Electrical system; Rep.  
gr. 93 ; General warning instructions for work on the high-  
voltage system .  
♦ If work on high-voltage system components is necessary, de-  
energise high-voltage system ⇒ Rep. gr. 00 ; Safety precau‐  
tions or ⇒ Electrical system; Rep. gr. 93 ; General warning  
instructions for work on the high-voltage system .  
The engine should only be started after the refrigerant circuit  
has been assembled completely.  
On vehicles with battery cooling, hybrid operation is only pos‐  
sible with the air conditioner charged and with no air condi‐  
tioner faults stored ⇒ Vehicle diagnostic tester in “Guided  
Fault Finding” mode for air conditioner and battery regulation  
After installing the electrically driven air conditioner compres‐  
sor and then charging the refrigerant circuit, first start up the  
compressor via the “Compressor run-in” function of the basic  
setting routine. Otherwise, the air conditioner compressor may  
be damaged if refrigerant oil has accumulated in the compres‐  
sion chamber of the air conditioner compressor due to inap‐  
propriate storage prior to installation. ⇒ Vehicle diagnostic  
tester, “Guided Fault Finding” function for air conditioner and  
battery regulation  
An electrically driven air conditioner compressor may only be  
activated when the refrigerant circuit is charged. Running the  
air conditioner compressor with the refrigerant circuit empty  
could lead to compressor damage ⇒ Vehicle diagnostic tester  
(“Guided Fault Finding” mode for air conditioner and battery  
regulation) .  
Before the refrigerant circuit can be discharged, evacuated  
and charged, specific electrically operated valves (may vary  
depending on the refrigerant circuit layout) must be opened  
(e.g. on the Audi Q7 e-tron) ⇒ Heating, air conditioning; Rep.  
gr. 87 ; Refrigerant circuit and ⇒ Vehicle diagnostic tester in  
“Guided Fault Finding” mode.  
To check whether the air conditioner is functioning properly,  
specific electrically operated valves must be opened or closed  
(e.g. on the Audi Q7 e-tron) ⇒ Heating, air conditioning; Rep.  
gr. 87 ; Refrigerant circuit and ⇒ Vehicle diagnostic tester in  
“Guided Fault Finding” mode.  
Depending on the vehicle, high pressure may not be available  
at the service connection on the high-pressure side in all air  
conditioner operating modes (e.g. on the Audi Q7 e-tron). The  
senders installed in the refrigerant circuit must therefore be  
used to check that the air conditioner in these vehicles is func‐  
tioning properly ⇒ Heating, air conditioning; Rep. gr. 87 ;  
Refrigerant circuit and ⇒ Vehicle diagnostic tester in “Guided  
Fault Finding” mode.  
– 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 ; Charging battery  
26  
Rep. gr.87 - Air conditioning system