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 .
Working on the refrigerant circuit with the A/C service station can normally be performed without needing to disable the high voltage system.
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-).
Vehicles with Start/Stop System
On vehicles with the Start/Stop System, the engine could start automatically and cause serious personal injury.
- If the Start/Stop System is activated (recognizable by a message in the instrument cluster), it is possible to start the engine automatically.
- Make sure the Start/Stop System is deactivated when working on the vehicle (switch off ignition and turn on again as needed).
All Vehicles
- If it is suspected that chemicals were added to the refrigerant circuit to seal leaks, chemical substances to seal leaks in the refrigerant circuit (leak stop additive), do not connect the A/C service station and do not extract the refrigerant.
- Chemicals that seal leaks in the coolant circuit form deposits that affect the function of the A/C system and lead to failure of the A/C system and the A/C service station.
- Inform that customer that there are substances in the A/C system that are no approved by Audi.
The chemical materials (stop leak additive) for sealing leaks in the refrigerant circuit offered on the market are not approved by Audi AG. There are no permanent-, validity or material compatibility tests. Therefore, damage or malfunctions in the A/C system or the A/C Service Station cannot be excluded.
The stop leak additives offered on the open market have different physical and chemical properties, which can impair the function of the A/C system and the A/C Service Station and can even shut down the system completely.
Audi does not approve the use of chemicals to seal leaks in the refrigerant circuit (leak stop additives).
Chemical materials (leak stop additives) to seal leaks in the refrigerant circuit react with air or the moisture in the air and form deposits in the refrigerant circuit (and in the A/C service station) that lead to malfunctions in the valves and other components that come into contact with such chemicals. These deposits cannot be removed completely from the components (also not through cleaning/flushing with refrigerant R134a).
It is not possible to recognize chemical substances to seal leaks in the refrigerant circuit (leak stop additive) and the label that is supposed to come with them is usually not there. Therefore be careful when working with if you do not know its service history.
Accessories offer containers used to separate out these chemicals (used to seal leaks in the refrigerant circuit). Since Audi does not know composition and the physical and chemical properties of these materials, it is not possible to make a statement about their effectiveness and the deposition rate of these filters.
The Filter for Sealants VAS6592 offers a certain protection for the A/C service station. This filter is incorporated between the A/C service station and the Service connection on the low pressure side of the refrigerant circuit in a vehicle (the A/C service station may not be connection to the service connection of the high pressure side of the refrigerant circuit for draining, evacuating and measuring). This filter separate certain materials that were added to seal leaks in the refrigerant circuit. It prevents these materials from getting into the refrigerant and refrigerant oil in the A/C service station unchecked and doing damage. For the protection to work, it is necessary that the filter be changed in regular intervals and exactly according to the manufacturer specifications (described in the instructions provided). Audi does not support using chemical materials (stop leak additives) for sealing leaks in the refrigerant circuit. There are many different formulas of these chemicals (stop leak additives), that are offered as "sealant for refrigerant circuits" and it is not possible to make a statement about the effectiveness of the Filter for Sealants VAS6592.
If the refrigerant circuit gets filed with a chemical material (stop leak additive) to seal any leaks (or if there is a suspicion of this) and if it then necessary to perform a repair to the refrigerant circuit, then it is necessary to inform the customer of the following:
- It is not possible to evacuate the refrigerant from the A/C system due to the stop leak additive that has been added to the system because it will damage the A/C Service Station. It will necessary to hire an outside company the can evacuate the contaminated refrigerant with a suitable device and then dispose of it (for example, a local waste management company that specializes in disposing of refrigerant).
- It will be necessary to replace any refrigerant circuit components that have come in contact with the stop leak additive in order to repair the A/C system properly. Certain refrigerant circuit components may already be damaged by the stop leak additive (for example, the A/C Compressor Regulator Valve -N280-) or will get damaged if they are used over again and will fail after a short amount of time. In addition to this, if there is any sediment from the stop leak additive still in the circuit, it could come loose at a later point and cause the A/C system to fail again (currently it is not possible to clean these components with any workshop tools).
Working on the A/C system refrigerant circuit
Refer to SERVICE STATION, IMPORTANT USAGE INFORMATION
Refer to SERVICING STATION, CONNECTING FOR MEASURING AND TESTING
Refer to REFRIGERANT CIRCUIT, DISCHARGING WITH SERVICE STATION
Refer to REFRIGERANT CIRCUIT, DISCHARGING WITH SERVICE STATION
Refer to REFRIGERANT CIRCUIT, CHARGING WITH SERVICE STATION
Refer to A/C SYSTEM, OPERATING AFTER CHARGING
Refer to REFRIGERANT TO SERVICE STATION RESERVOIR (CHARGING CYLINDER OR RESERVOIR BOTTLE), TRANSFERRING
Refer to SERVICE STATION, DRAINING