Air conditioner with refrigerant R134a.pdf

Service

Workshop Manual

Audi 100 1991 ➤ , Audi 80 1992 ➤ ,

Audi A1 2011 ➤ , Audi A2 2001 ➤ ,

Audi A3 1997 ➤ , Audi A3 2004 ➤ ,

Audi A4 1995 ➤ , Audi A4 2001 ➤ ,

Audi A4 2008 ➤ ,

Audi A4 Cabriolet 2003 ➤ ,

Audi A5 Cabriolet 2009 ➤ ,

Audi A5 Coupé 2008 ➤ ,

Audi A5 Sportback 2010 ➤ ,

Audi A6 1995 ➤ , Audi A6 1998 ➤ ,

Audi A6 2005 ➤ ,

Audi A7 Sportback 2011 ➤ ,

Audi A8 1994 ➤ , Audi A8 2003 ➤ ,

Audi A8 2010 ➤ , Audi Cabriolet 1991 ➤ ,

Audi Q5 2008 ➤ , Audi Q7 2007 ➤ ,

Audi R8 2007 ➤ , Audi TT 1999 ➤ ,

Audi TT 2007 ➤

Air conditioner with refrigerant R134a

Edition 06.2010

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.

Service Department. Technical Information

Service

List of Workshop Manual Repair GroupsList of Workshop Manual

Repair GroupsList of Workshop Manual Repair Groups

Repair Group

87 - Air conditioning system

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.

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.

No reproduction without prior agreement from publisher.

A0053300220

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...

Air conditioner with refrigerant R134a - Edition 06.2010

Contents

87 - Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 General information on air conditioning systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Other reference material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.3 Principles of air conditioning systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.4 Refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.5 Properties of refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.6 Refrigerant oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.7 How air conditioning works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.8 General work safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.9 Product properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.10 Handling refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.11 Handling pressure vessels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.12 Safety regulations for working with extraction and charging systems . . . . . . . . . . . . . . . . 12

1.13 Safety measures for working on vehicles with air conditioning system and for handling

refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.14 Basic rules for working on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.15 Before using air conditioner after system has been re-charged . . . . . . . . . . . . . . . . . . . . . . 15

2 General information on refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.1 Components of refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.2 Arrangement of the refrigerant circuit components and their influence on the high and low-

pressure ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.3 Design of refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.4 Connections for quick-release coupling in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . 26

2.5 Switches and senders in refrigerant circuit and related connections . . . . . . . . . . . . . . . . 28

2.6 Electrical components not installed in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.7 Pressures and temperatures in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2.8 Test and measurement operations which can be performed with a pressure gauge . . . . 37

2.9 Air conditioner service and recycling units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2.10 Repair notes for refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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.

Laws and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3.1

Laws and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.1

Important repair notes for air conditioning systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.2

Converting refrigerant circuits from refrigerant R12 to refrigerant R134a . . . . . . . . . . . . . . 45

4.3

Working with the air conditioner service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4.4

Blowing out refrigerant circuit with compressed air and nitrogen . . . . . . . . . . . . . . . . . . . . 55

4.5

Flushing (cleaning) refrigerant circuit with refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . 59

4.6

Tracing leaks in refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Problems with refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

5.1

Possible complaints about refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Connecting air conditioner service station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

6.1

Connecting air conditioner service station on vehicles with a connection on the low and high-

pressure end of the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

6.2

Connecting air conditioner service station on vehicles with no connection on the low-pressure

end of the refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Checking pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

7.1

Checking pressures in refrigerant circuit with air conditioner service station (with ignition

switched off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

7.2

Checking pressures on vehicles with a restrictor and reservoir (with internally regulated air

conditioner compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

7.3

Checking pressures on vehicles with an expansion valve and receiver (with internally

regulated air conditioner compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Contents i

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...

Air conditioner with refrigerant R134a - Edition 06.2010

7.4 Checking pressures on vehicles with restrictor, reservoir and air conditioner compressor

regulating valve N280 (with externally regulated air conditioner compressor) . . . . . . . . . . 118

7.5 Checking pressures on vehicles with expansion valve, receiver and air conditioner

compressor regulating valve N280 (with externally regulated air conditioner compressor)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

8 Renewing components of refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

8.1 Renewing components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

9 Capacities for refrigerant R134a, refrigerant oil and approved refrigerant oils . . . . . . . . . . 144

9.1 Capacities for refrigerant R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

9.2 Approved refrigerant oils and refrigerant oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

10 Test equipment and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

10.1 List of testers, tools and materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

10.2 Tools and materials available from regional sales centre or importer . . . . . . . . . . . . . . . . 191

10.3 Commercially available tools and materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

10.4 Improvised tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

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.

ii Contents

Audi 100 1991 ➤ , Audi 80 1992 ➤ , Audi A1 2011 ➤ , Audi A2 2001 ➤ , A ...

Air conditioner with refrigerant R134a - Edition 06.2010

87 – Air conditioning system

1 General information on air condition‐

ing systems

♦ Introduction ⇒ page 1

♦ Other reference material ⇒ page 1

♦ Principles of air conditioning systems ⇒ page 2

♦ Refrigerant R134a ⇒ page 4

♦ Properties of refrigerant R134a ⇒ page 5

♦ Refrigerant oil ⇒ page 7

♦ How air conditioning works ⇒ page 8

♦ General work safety ⇒ page 10

♦ Product properties ⇒ page 10

♦ Handling refrigerant ⇒ page 10

♦ Handling pressure vessels ⇒ page 11

♦ Safety regulations for working with extraction and charging

systems ⇒ page 12

♦ Safety measures for working on vehicles with air conditioning

system and for handling refrigerant R134a ⇒ page 13

♦ Basic rules for working on refrigerant circuit ⇒ page 14

♦ Before using air conditioner after system has been re-charged

⇒ page 15

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

permitted unless aut horised by AUD I AG. AUDI AG does not guarantee or accept any liability

with respect to the correctness of information in this document. Copyright by AUDI AG.

1.1 Introduction

This manual is intended to provide foremen and mechanics with

the basic knowledge needed to ensure reliable and successful

repairs.

Note

This requires careful study of the manual, coupled with suitable

training on automotive air conditioning systems (with a qualifica‐

tion test if applicable) and the ability to apply the acquired exper‐

tise in practice.

This document is a compact reference work which should be kept

at the workplace. It should also be available for presentation to

the responsible supervisory agency on request.

1.2 Other reference material

♦ Workshop manual for model-specific servicing work ⇒ Heat‐

ing, air conditioning; Rep. gr. 87 or ⇒ Air conditioning; Rep.

gr. 87 (vehicle-specific workshop manual) and ⇒ Current flow

diagrams, Electrical fault finding and Fitting locations

♦ Technical Service Handbook (TPI) outlining action to be taken

to rectify current problems

♦ Self-study programmes, e.g. ⇒ Self-study programme No.

208 ; Air conditioning systems in motor vehicles

♦ Video training courses for dealerships

1. General information on air conditioning systems 1

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