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Removing and installing air conditioner compressor > < Removing and installing air conditioner operating and display unit, Climatronic control unitJ255

A5

Removing and installing battery cooling module
Removing and installing battery cooling module
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.
Removing
–  Switch off the ignition.
–  Drain the refrigerant circuit → Air conditioner with refrigerant R134a.
–  Remove the supply air duct for the drive battery → Chapter.
   
–  Screw out the bolts -2, 3- and detach the refrigerant lines -1, 4-.
  Note
Seal the open pipes and the connections at the refrigerant line with suitable caps (to prevent the ingress of dirt and moisture).
  A87-11125
–  Unplug and lay bare the connectors -1, 2-.
–  Unscrew the nuts -arrows- and detach the battery cooling module.
Installing
Install in reverse order; paying attention to the following:
  Note
t  Heed the fitting instructions for O-rings → Chapter.
t  Following attachment, check the routing of the refrigerant lines. They must be inserted in the holders provided and not make contact with other components.
  A87-11137
–  Replace the O-rings -4-, for version, refer to → Electronic parts catalogue.
–  Clean the refrigerant line connections -3, 5- and check for damage.
–  Pay attention to correct positioning of the O-rings -4- in the grooves of the corresponding mount.
–  Check the fitted pin -2- (not provided at all connections) for damage and proper attachment.
–  Tighten the bolts -1-.
–  Install the refrigerant lines to the battery cooling module in the luggage compartment → Chapter.
–  Re-install the remaining components removed.
–  For electrical connections and routing, refer to → Current flow diagrams, Electrical fault finding and Fitting locations.
–  Evacuate and charge the refrigerant circuit → Air conditioner with refrigerant R134a.
–  Switch on the ignition.
–  Interrogate the event recorder of the operating and display unit, Climatronic control unit -J255- and erase any faults displayed → "Guided fault-finding" function of vehicle diagnostic tester.
–  Start up the air conditioner after charging the refrigerant circuit → Chapter.
  Note
Also heed the notes on start-up of the air conditioner after charging → Air conditioner with refrigerant R134a.
  A87-11043

Removing and installing air conditioner compressor > < Removing and installing air conditioner operating and display unit, Climatronic control unitJ255