General Information
Vehicles with a High Voltage System (Hybrid Vehicles)
Read and follow all of the supplemental warnings for all work performed on vehicles with the high voltage system. Refer to WARNINGS WHEN WORKING ON VEHICLES WITH HIGH VOLTAGE SYSTEM and HIGH VOLTAGE SYSTEM GENERAL WARNINGS for CAEB & CAED Engines, HIGH VOLTAGE SYSTEM GENERAL WARNINGS for CPMA & CPMB Engines or HIGH VOLTAGE SYSTEM GENERAL WARNINGS for CCBA, CGXC & CTUB .
Risk of unintended engine start
The ignition must be turned off and the ignition key must remain outside of the vehicle when working on vehicles with a high voltage system.
Handling high voltage cables:
- Do not stand on or place tools on high voltage cables and their components as it may damage the cable insulation.
- Never bend or kink high voltage cables forcefully as it may damage the cable insulation.
- The round high voltage connectors are color coded with an external color ring and are mechanically coded using the guide- or code tabs. Always make certain that the coding matches when connecting the round connector in order to avoid any mechanical damage the high voltage connector.
There is a risk of electrocution from damaged high voltage components.
Observe the following when working around high voltage components and high voltage wires:
- Never work around high voltage components and cables with cutting, deformed, or sharp edged tools, or heat sources such as welding or soldering tools, heated air, and thermal glue.
- Inspect the high voltage components visually before beginning.
- Perform a visual inspection of the Electric Drive Power and Control Electronics -JX1-, the Electro-Drive Drive Motor -V141-, the Electrical A/C Compressor -V470- and the high voltage lines when working in the engine compartment.
- Perform a visual inspection of the high voltage lines and covers when working on the underbody.
- Perform a visual inspection of the high voltage lines and the Electrobox with the High Voltage System Maintenance Connector -TW- when working in the luggage compartment.
- Perform a visual inspection on all of the potential equalization cables.
Observe the following items when performing the visual inspection:
- The components do not display any signs of external damage.
- The high voltage cable insulation and the potential equalization cables are not damaged.
- The high voltage cables do not display any abnormal deformations.
- Every high voltage component is marked with a red warning label.
If it is necessary to perform work in the vicinity of high voltage components, perform a "visual inspection" of the high voltage components and cables for damages (refer to PERFORMING A VISUAL INSPECTION OF DAMAGE TO HIGH VOLTAGE COMPONENTS AND CABLES ) and follow the HIGH VOLTAGE SYSTEM GENERAL WARNINGS for CAEB & CAED Engines, HIGH VOLTAGE SYSTEM GENERAL WARNINGS for CPMA & CPMB Engines or HIGH VOLTAGE SYSTEM GENERAL WARNINGS for CCBA, CGXC & CTUB .
If it is necessary to perform work on the high voltage components, disable the high voltage system. and read and follow the HIGH VOLTAGE SYSTEM GENERAL WARNINGS for CAEB & CAED Engines, HIGH VOLTAGE SYSTEM GENERAL WARNINGS for CPMA & CPMB Engines or HIGH VOLTAGE SYSTEM GENERAL WARNINGS for CCBA, CGXC & CTUB .
Disable the high voltage system
Risk of electrocution
Death or serious bodily injury by electric shock.
- The high voltage system may only be activated by qualified personnel (Audi high voltage mechanic).
- Make sure that the high voltage system is completely disabled. Make sure the vehicle is de-energized using "Guided Fault Finding " on the Vehicle Diagnostic Tester.
- The qualified personal (Audi high voltage technician) determines the voltage and secures the system from restarting using the Service Disconnect Lock T40262. Keep the ignition key and the High Voltage System Maintenance Connector -TW- safely with the qualified personal to secure the system from restarting.
- The Audi high voltage technician should put a sign on the vehicle to identify it as a high voltage vehicle.
Disable the high voltage system:
Connect the Vehicle Diagnostic Tester.
Select the Guided Fault Finding mode.
Using the GO TO button, select the following menu commands
Function/Component Selection
Body
Electrical Equipment
OBD-capable systems
8C - Battery Regulation Control Module -J840
8C - Battery Regulation Control Module, functions
51 - De-energize the high voltage
Restart the high voltage system
Risk of electrocution
Death or serious bodily injury by electric shock
- The high voltage system may only be restarted by qualified personal (Audi high voltage technicians).
- Make sure the vehicle is energized using the "Guided Fault Finding " on the Vehicle Diagnostic Tester.
- The qualified personal (Audi high voltage technician) restarts the vehicle.
- The Audi high voltage technician should put a sign on the vehicle to identify it as a high voltage vehicle.
Restart the high voltage system:
Connect the Vehicle Diagnostic Tester.
Select the Guided Fault Finding mode.
Using the GO TO button, select the following menu commands
Function/Component Selection
Body
Electrical Equipment
OBD-capable systems
8C - Battery Regulation Control Module -J840
8C - Battery Regulation Control Module, functions
51 - High voltage restart (Repair Group 93)
The engine may start unexpectedly when performing work while the ignition is turned on or when the ready mode is activated and may cause poisoning in enclosed spaces. Be aware of body limbs and/or clothing when clamping or pulling.
Perform the following steps before turning on the ignition:
- Move the selector lever into position P.
- Activate the parking brake.
- Switch off ignition.
- Open the engine hood.
- Connect the charging unit for example Battery Charger VAS 5095A to the battery jump start terminal for the 12V vehicle electrical system
- Switch on the ignition.
-- Charge the vehicle battery, for example, using the Battery Charger VAS5904 in the battery support mode to minimize the number of automatic starts during the test- and measuring procedures while the ready mode is active. Refer to BATTERY, CHARGING and HIGH VOLTAGE SYSTEM GENERAL WARNINGS for CAEB & CAED Engines, HIGH VOLTAGE SYSTEM GENERAL WARNINGS for CPMA & CPMB Engines or HIGH VOLTAGE SYSTEM GENERAL WARNINGS for CCBA, CGXC & CTUB .
-- Move the selector level into position "P", activate the parking brake and arrange the necessary tools for testing and measuring procedures that require the ready mode to be active or that require the ignition to be on, so that they cannot come into contact with the turning components in the engine and so that they are not in the vicinity of the turning components of a running engine.
Also move the selector lever into position "P" and activate the parking brake for testing and measuring procedures which require the ignition to be on, but do not require the ready mode to be active.
The ready mode is displayed in the Instrument Cluster Control Module -J285- above the "powermeter". Refer to Owner's Manual.
Activate and deactivate the ready mode. Refer to Owner's Manual (consult the display in the Instrument Cluster Control Module -J285-).
All vehicles
Compressed air and nitrogen are to be used in order to force out moisture and other contaminants as well as old refrigerant oil as efficiently as possible, without wasting refrigerant. In the refrigerant circuit is to be cleaned (flush with refrigerant R134a or blow through with compressed air and nitrogen)
For the most part, blowing through the refrigerant circuit with compressed air and nitrogen requires significantly more work than cleaning (flushing) with refrigerant R134a. As cleaning (flushing) with refrigerant R134a cleans the components more efficiently, always flush in case of a complaint (blowing through should only be used for certain complaints and individual components).
Under certain conditions it may be sufficient to blow through certain components (e.g. individual refrigerant lines or refrigerant hoses) with compressed air and nitrogen (e.g. for purposes of forcing out old refrigerant oil from individual components that were removed).
Certain contaminants cannot or can only be insufficiently removed from the refrigerant circuit with compressed air, these contaminants can be removed, for example by cleaning (flushing) with refrigerant R134a. Refer to REFRIGERANT CIRCUIT, CLEANING (FLUSHING), WITH REFRIGERANT R134A .
When blowing through, the maximum work pressure of 15 bar (217 psi) must not be exceeded (corresponding to pressure that is reached in a filled refrigerant circuit with an ambient temperature of approximately 60 °C (140 °F), if necessary use pressure reducer also for compressed air)
- Nitrogen can leak uncontrolled from the cylinder.
- Make exclusive use of pressure reducers for nitrogen cylinders (maximum work pressure 15 bar (217 psi)).
- Use appropriate extraction units to draw off gas mixture escaping from components.
-- Always flush components in direction opposite to refrigerant flow.
Restrictor, expansion valve, compressor, receiver and reservoir cannot be flushed with compressed air and nitrogen.
-- Remove this dryer cartridge on condensers that have one installed in the integrated receiver/dryer.
If the receiver/dryer or dryer cartridge is integrated in the condenser, then they cannot be replaced separately and the condenser must be replaced after cleaning (flushing).
Receivers/dryers where it is possible to replace the dryer cartridge have an additional filter, which must also be replaced with the dryer cartridge.
-- First flush out old refrigerant oil and dirt using compressed air and then use nitrogen to remove component moisture.
-- Adapter for sealing off the pressure hose to the refrigerant circuit. Refer to A/C SERVICE STATION, CONNECTING .
Note the following points to prevent oil and moisture from entering the refrigerant circuit from the compressed air system.
-- The compressed air must be routed through a compressed air purifier for cleaning and drying. For this reason use the filter and dryer for the compressed air (included in scope of delivery as tool for painting work).
-- On refrigerant lines with thread or union nut on the connection, use the adapter from the A/C Adapter Set VAG1785 (A/C Adapter Set - Adapter 1 VAG1785/1 through A/C Adapter Set - Adapter 8 VAG1785/8) to connect charge hoses 5/8" -18 UNF (a section of this adapter is also contained in the Refrigerant Circuits Adapter Set 1 VAS6338/1.
-- On refrigerant lines without thread or union nut on the connection (for connecting adapters), use adapter from Refrigerant Circuits Adapter Set 1 VAS6338/1 or a standard blower pistol with rubber mouthpiece.
Only blow through refrigerant circuit with compressed air and then with nitrogen if there is no possibility of cleaning (flushing) the refrigerant circuit with refrigerant R134a or the amount of work to flush individual components becomes excessive (for example minor contaminants and moisture can also be blown out of the refrigerant lines in a short period of time).
Compressed air/nitrogen emerging from components is to be drawn off by way of an appropriate system (for example, a workshop extraction system).
The circuit (or individual components) must be blown through (if there is no possibility for cleaning or flushing with refrigerant R134a is not recommended):
-- In the event dirt or other contaminants are located in individual components of the circuit.
-- If vacuum reading is not maintained on evacuating a leak-free refrigerant circuit (pressure build-up due to moisture in refrigerant circuit).
-- The refrigerant circuit has been left open for longer than normal (for example, following an accident).
-- Pressure and temperature measurements in the refrigerant circuit indicate the likelihood of moisture.
-- In the event of doubt about the amount of refrigerant oil in the circuit.
-- The A/C compressor had to be replaced on account of internal damage (for example, noise or no output).
Pay attentions when replacing the Electrical A/C Compressor -V470- on vehicles with electrically driven A/C compressor (if the electronic on the A/C compressor is damaged the refrigerant circuit must not always be cleaned. Refer to COMPRESSOR, REPLACING WITHOUT THE NEED FOR FLUSHING REFRIGERANT CIRCUIT .
-- If it is stipulated by the vehicle-specific repair information following the replacement of certain components.
Certain contaminants and old refrigerant oil cannot or can only be insufficiently removed from the refrigerant circuit with compressed air, these contaminants can be removed, for example, by cleaning (flushing) with refrigerant R134a. Refer to REFRIGERANT CIRCUIT, CLEANING (FLUSHING), WITH REFRIGERANT R134A .