A/C System, General Information: Introduction
The purpose of this repair information is to provide foremen and mechanics with the basic knowledge needed to ensure expert working.
Only the careful study of this documentation, practical implementation of the information contained, training on Air Conditioning (A/C systems and expert knowledge (with or without certificate) can guarantee expertise in the field of motor vehicle A/C systems.
This document is a compact reference work which should be kept at the workplace. It should also be available for presentation to the responsible supervisory agency on request.
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 .
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.
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
Non-approved tools or materials such as leak sealing additives can cause damage or malfunctions in the system.
Only use tools and materials approved by the manufacturer.
The warranty is voided if non-approved tools or materials are used.