audi Workshop Repair Guides

Audi Workshop Service and Repair Manuals

ABOUT US
Components for control and regulation of air conditioner located in passenger compartment > < Moving battery cooling module to service position

A4 Mk3

Checking, removing and installing battery cooling module condensation drain
Checking, removing and installing battery cooling module condensation drain
Vehicles with a high-voltage system (hybrid vehicles)
For all work on vehicles with a high-voltage system, pay attention to the additional warnings for such vehicles → Chapter and → Electrical system; Rep. gr.93.
As work in the vicinity of high-voltage system components is necessary for the following sequence of operations, perform „Visual inspection of high-voltage components and cables for damage“ → Chapter and heed the „General warnings for working on high-voltage system“ → Electrical system; Rep. gr.93
  WARNING
Danger from unexpected engine starting
When performing general work on vehicles with a high-voltage system, switch off the ignition and remove the ignition key from the passenger compartment.
  WARNING
Working on vehicles with high-voltage wiring:
l  Do not support yourself or tools on high-voltage wiring or associated components --> this can damage the insulation.
l  High-voltage wiring must not be excessively bent or kinked --> this can damage the insulation.
l  The round high-voltage connectors are colour-coded with an external coloured ring and are provided with mechanical coding or guide lugs. It is important to observe this coding when joining up the round high-voltage connectors, otherwise the connectors can be damaged.
  DANGER!
Risk of fatal injury if high-voltage components are damaged.
Observe the following when working in the vicinity of high-voltage components or wiring:
t  It is not permitted to use cutting or forming tools, other sharp-edged tools or heat sources such as welding, brazing, soldering, hot air or thermal bonding equipment.
t  Before starting work, visually inspect the high-voltage components in the areas involved.
t  Before working in the engine compartment, visually inspect the power electronics -JX1-, electric drive motor -V141-, air conditioner compressor -V470- and high-voltage wiring.
t  Before working on the vehicle underbody, visually inspect the high-voltage wiring and covers.
t  Before working on the rear section of the vehicle, visually inspect the high-voltage wiring and the electro-box with the maintenance connector for high-voltage system - TW -.
t  Visually inspect all potential equalisation lines.
Check the following when making the visual inspection:
t  There must be no external damage on any component.
t  The insulation of the high-voltage wiring and potential equalisation lines must not be damaged.
t  There must be no unusual deformation of the high-voltage wiring.
t  All high-voltage components must be identified by a red warning sticker.
Checking
–  Switch off the ignition.
–  Remove the luggage compartment floor → General body repairs, interior; Rep. gr.70.
–  Move the battery cooling module to service position → Chapter.
   
–  Check the condensation drain -3- for dirt and proper installation
Removing
–  Remove the luggage compartment floor → General body repairs, interior; Rep. gr.70.
–  Move the battery cooling module to service position → Chapter.
  A87-11147
–  Unscrew the nuts -2- and -3- and press the heat shield slightly to the left.
–  Carefully release -arrows- the fasteners of the plastic ring and press the condensation drain into the battery recess.
–  Detach the condensation drain from the retainer.
Installing
Install in reverse order; paying attention to the following:
  Note
t  Replace the condensation drain if the plastic ring is damaged.
t  Seal the plastic ring with silicone compound if slightly out of shape.
  A87-11145
–  Pay attention to the installation position when fitting the plastic ring:
l  The lug -1- of the plastic ring must be positioned between the two marks on the condensation drain -arrows-.
  A87-11146
–  Fit the condensation drain -arrow A- such that the lug -1- engages in the recess -2- in the retainer.
–  Fit the socket in the opening in the battery recess. When doing so, insert the lug -4- upwards and engage at the bottom.
  Note
t  If the socket does not provide a full seal with the battery recess, apply e.g. silicone adhesive sealant -D 176 001 A3- at this location → Electronic parts catalogue.
t  The bonding surface must be clean and free from grease when applying the silicone adhesive sealant.
  A87-11147
–  Check correct positioning of the condensation drain.
l  The lug -2- must face the bead -1- in the retainer.
–  Re-install the remaining components removed.
–  Switch on the ignition.
–  After installation, interrogate the event recorder of the operating and display unit, Climatronic control unit -J255- and the battery regulation control unit -J840-, erase any faults displayed and perform basic setting for the two control motors at the battery cooling module → "Guided fault-finding" function of vehicle diagnostic tester.
  A87-11148

Components for control and regulation of air conditioner located in passenger compartment > < Moving battery cooling module to service position