| Working with the air conditioner service station |
| Vehicles with high-voltage system (hybrid vehicles) |
WARNING | Safety hazard: the engine can start unexpectedly. |
| Before carrying out general work on a vehicle with high-voltage electrical system, switch off the ignition and remove the ignition key from the vehicle. |
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WARNING | Working on vehicles with high-voltage wiring: |
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| Do not support yourself or tools on high-voltage wiring or associated components --> this can damage the insulation. |
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| High-voltage wiring must not be excessively bent or kinked --> this can damage the insulation. |
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| 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. |
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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: |
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| 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. |
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| Before starting work, visually inspect the high-voltage components in the areas involved. |
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| Before working in the engine compartment, visually inspect the power electronics -JX1-, electric drive motor -V141-, air conditioner compressor -V470- and high-voltage wiring. |
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| Before working on the vehicle underbody, visually inspect the high-voltage wiring and covers. |
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| 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 -. |
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| Visually inspect all potential equalisation lines. |
| Check the following when making the visual inspection: |
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| There must be no external damage on any component. |
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| The insulation of the high-voltage wiring and potential equalisation lines must not be damaged. |
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| There must be no unusual deformation of the high-voltage wiring. |
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| All high-voltage components must be identified by a red warning sticker. |
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| If work is necessary in the vicinity of high-voltage system components, perform a visual inspection of the high-voltage components and wiring to check for damage → Chapter and note → Electrical system; Rep. gr.93. |
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. |
| De-energising high-voltage system |
DANGER! | Voltage can cause fatal injury. |
| Danger of severe or fatal injuries from electric shock. |
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| For reasons of safety, persons with life-preserving or other electronic medical devices in or on their body must not perform any work on the high-voltage system. Such medical devices include internal analgesic pumps, implanted defibrillators, pacemakers, insulin pumps and hearing aids. |
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| The high-voltage system may only be de-energised by a suitably qualified person (Audi high-voltage technician). |
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| It must be definitely confirmed that the high-voltage system is de-energised. The system may only be de-energised using the vehicle diagnostic tester via „Guided Fault Finding“. |
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| The qualified person (Audi high-voltage technician) confirms that the system is de-energised and uses the locking cap -T40262- to ensure that the system cannot be re-energised. The ignition key and the maintenance connector for high-voltage system - TW - should then be stored in a safe place by the qualified person. |
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| The qualified person (Audi high-voltage technician) marks the vehicle by attaching the appropriate warning signs. |
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| De-energising high-voltage system: |
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| Connect vehicle diagnostic tester |
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| Select Guided Fault Finding mode |
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| Using the Go to key, select the following menu items in succession |
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| Function/component selection |
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| Self-diagnosis compatible systems |
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| 8C - Hybrid battery management -J840 |
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| 8C - Hybrid battery management, functions |
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| 51 - De-energise high-voltage system (Rep. gr. 93) |
| Re-energising high-voltage system |
DANGER! | Voltage can cause fatal injury. |
| Danger of severe or fatal injuries from electric shock. |
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| For reasons of safety, persons with life-preserving or other electronic medical devices in or on their body must not perform any work on the high-voltage system. Such medical devices include internal analgesic pumps, implanted defibrillators, pacemakers, insulin pumps and hearing aids. |
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| The high-voltage system may only be re-energised by a suitably qualified person (Audi high-voltage technician). |
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| The system may only be re-energised using the vehicle diagnostic tester via „Guided Fault Finding“. |
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| The vehicle is then made ready for operation again by the qualified person (Audi high-voltage technician). |
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| The qualified person (Audi high-voltage technician) marks the vehicle by attaching the appropriate warning signs. |
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Note | t
| Re-energise high-voltage system: |
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| Connect vehicle diagnostic tester |
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| Select Guided Fault Finding mode |
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| Using the Go to key, select the following menu items in succession |
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| Function/component selection |
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| Self-diagnosis compatible systems |
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| 8C - Hybrid battery management -J840 |
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| 8C - Hybrid battery management, functions |
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| 51 - Re-energise high-voltage system (Rep. gr. 93) |
DANGER! | When working on a vehicle with the ignition switched on or while the drive system is active, the engine can start unexpectedly and exhaust fumes can cause a health hazard in closed rooms. Moving parts can trap or draw in parts of the body and/or clothing (safety hazard). |
| Before switching on the ignition, perform the following steps: |
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| Move selector lever to position P |
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| Connect battery charger (e.g. -VAS 5095A-) to jump-start connections of 12 V electrical system |
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| For test and measurement work that requires the vehicle's drive system to be active or the ignition to be switched on, move the selector lever to position „P“, activate the parking brake and arrange the tools needed so that they cannot come into contact with moving components of the engine and so that they cannot even come near to components that turn when the engine is running. |
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| 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. |
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| The status of the drive system is shown by the control unit in dash panel insert -J285- via the „power meter“ → Owner's Manual. |
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| Activating and deactivating drive system → Owner's Manual (note display of control unit in dash panel insert -J285-). |
| Vehicles with start/stop system |
WARNING | Injury risk due to automatic engine start (vehicles with start/stop system). |
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| On vehicles with an activated start/stop system (indicated by a message in the instrument cluster display), the engine may start automatically on demand. |
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| Therefore, please make sure that the start/stop system is deactivated when performing repair work on the vehicle (switch off the ignition, and switch it on again if required). |
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| If there is a possibility that chemical substances (sealing additives) for sealing leaks have been added to the refrigerant circuit from which the refrigerant is to be extracted, do not connect the air conditioner service station to this refrigerant circuit and do not extract the refrigerant. |
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| Chemical substances (sealing additives) for sealing leaks form deposits in the refrigerant circuit which will impair operation of the air conditioning system and lead to failure of the system (and of the air conditioner service station). |
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| Customers should be informed that the air conditioner in their vehicle contains substances not approved by Audi and that the system can therefore not be discharged and serviced by your workshop. |
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| Commercially available chemical substances (sealing additives) for sealing refrigerant circuit leaks are not approved by Audi AG. Damage to or malfunctioning of the air conditioner or air conditioner service station cannot be precluded as no tests have been performed to establish long-term action, effectiveness and material compatibility. |
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| Commercially available sealing additives have different physical and chemical properties. They may have a lasting detrimental effect on operation of the air conditioner and air conditioner service station or even be the cause of total failure. |
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| Audi does not permit the use of chemical substances (sealing additives) to seal leaks in the refrigerant circuit. |
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| Chemical substances (sealing additives) for sealing leaks in the refrigerant circuit generally react with the ambient air or the humidity contained in it. They cause malfunctioning of valves and other components with which they come into contact on account of deposits in the refrigerant circuit (and in the air conditioner service station being used). These deposits cannot be completely removed from the components (even by flushing). |
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| Chemical substances (sealing additives) for sealing leaks in the refrigerant circuit are normally not outwardly apparent and the identification stickers which should be affixed are usually non-existent. Vehicles with an unknown history should therefore be treated with due caution. |
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| On the accessories market, vessels with integrated filters are available which are supposed to intercept these chemical substances (additives used to seal leaks). As Audi are not aware of the composition and thus the physical and chemical properties of these substances, no information can be given here as to the effectiveness and the separation rate of such filters. |
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| The sealant filter -VAS 6592- available as "Workshop equipment" provides a certain degree of protection for air conditioner service stations. This filter is incorporated between the air conditioner service station and the service connection on the low-pressure end of the vehicle refrigerant circuit (the air conditioner service station is not to be attached to the service connection on the high-pressure end of the refrigerant circuit for drainage, evacuation and measurement). The filter separates out certain substances added to the circuit to seal refrigerant circuit leaks. It thus prevents the unimpeded and unrestricted ingress of these substances into the air conditioner service station (together with the refrigerant and refrigerant oil) where they would cause damage. Protection is however only provided if the built-in filter is renewed at regular intervals exactly as specified by the manufacturer in the applicable instructions. As Audi do not approve the use of chemical substances (sealing additives) for sealing leaks in the refrigerant circuit and the composition of such chemical substances (sealing additives) marketed for example as so-called „refrigerant circuit sealants“ varies greatly, it is again not possible to provide any information on the action and efficiency of the sealant filter -VAS 6592-. |
| If air conditioner refrigerant circuit repair work has to be performed on a vehicle on which chemical substances (sealing additives) have been added to the refrigerant circuit to seal leaking components (or even if this is just strongly suspected), the customer (vehicle owner) is to be made aware of the following: |
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| The air conditioner refrigerant cannot be extracted on account of the substances added (sealing additives), as these could damage the air conditioner service station. The refrigerant must be extracted for example by a company authorised to extract and then dispose of the contaminated refrigerant using the appropriate equipment (e.g. a local refuse disposal company specialising in the disposal of refrigerants). |
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| The air conditioner can only be properly repaired by renewing all the refrigerant circuit components which have come into contact with the sealing additive. The sealing additive may already have damaged certain refrigerant circuit components (e.g. the air conditioner compressor regulating valve -N280-) or lead to damage and subsequent failure shortly after renewed start-up. Furthermore, sealing additive deposits may subsequently work loose in the refrigerant circuit components and then lead to renewed failure of the air conditioner (complete cleaning of these components with workshop equipment is not possible at present). |
| Work on the air conditioner refrigerant circuit |
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| Important notes for working with the air conditioner service station → Chapter. |
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| Connection of the air conditioner service station for measurement and testing → Chapter. |
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| Refrigerant circuit discharge using the air conditioner service station → Chapter. |
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| Evacuate refrigerant circuit with air conditioner service station → Chapter. |
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| Refrigerant circuit charging using the air conditioner service station → Chapter. |
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| Air conditioner start-up after charging → Chapter. |
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| Pouring refrigerant into the charging cylinder or storage vessel of the air conditioner service station → Chapter. |
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| Air conditioner service station drainage → Chapter. |
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