Audi Q3: A/C System and Refrigerant R134a Safety Precautions
Vehicles with a high-voltage system (hybrid vehicles)
Extremely Dangerous Due to High-Voltage
The high-voltage system is under high-voltage. Electrocution can
cause death or very serious personal injury from damages high-voltage
components and high-voltage cables.
- Perform a visual inspection of the high-voltage components and the
high-voltage cables.
- Never use tools that are for cutting, deformed, or sharp edged.
- Never use welding, soldering, thermal adhesive or hot air.
There is a Risk of Injury from the Engine Starting Unexpectedly
On electric - hybrid vehicles an active ready mode is difficult to
identify. Parts of the body can be clamped or pulled.
- Turn off the ignition.
- Place the ignition key outside of the vehicle interior.
Risk of Damaging the High-Voltage Cables
Misuse can damage the insulation of high-voltage cables or
high-voltage connectors.
- Never support objects on the high-voltage cables and the
high-voltage connectors.
- Never support tools on the high-voltage cables and the high-voltage
connectors.
- Never sharply bend or kink the high-voltage cables.
- When connecting pay attention to the coding of the high-voltage
connectors.
For all procedures on vehicles with high-voltage system pay
attention to the additional warning message for these vehicles.
Refer to
→ Chapter "Warnings when Working on Vehicles with High Voltage
System".
Vehicles with Start/Stop System
There is a Risk of Injury from the Engine Starting Unexpectedly
The engine can start unexpectedly on vehicles with an activated
Start/Stop System. A message appears in the instrument cluster
indicating whether the Start/Stop System is activated.
- Deactivate the Start/Stop System: Turn off the ignition.
All Vehicles
WARNING
Asphyxiation, frostbite, and poisoning may occur as
a result of leaking refrigerant
There is a risk of injury from leaking refrigerant
- Danger of asphyxiation from displacement of the
surrounding air
- There is a risk of frostbite (or risk of freezer
burn from the evaporating liquid refrigerant)
- There is a risk of poisoning from the byproducts
Corrective Action
- Work on the A/C system refrigerant circuit should
only be performed in well ventilated areas.
- When handling refrigerant and working on the
refrigerant circuit, make sure there is a good flow of
oxygen (change the air at least one time each hour in
the work area and three times per hour in enclosed
spaces (for example, the work pit). Turn on the
available workshop ventilation and exhaust systems.
- Only store containers and devices with refrigerant
in well ventilated areas (not in basements or near
basement staircases for example).
- Do not breathe in fumes from leaking refrigerant.
- When handling refrigerant and when working on the
refrigerant circuit, wear suitable protective gloves and
protective eyewear.
- It is recommended to have an eye-flushing bottle
available.
- Work on the A/C system refrigerant circuit should
only be performed in well ventilated areas. Switch on
the available ventilation systems.
- Refrigerant must not be stored in low-lying areas
such as basements or in their entry ways or windowsills.
First Aid Measures
- If the affected person has inhaled a high
concentration of refrigerant vapors, immediately remove
them from the contaminated area and bring and lay them
in the fresh air. Keep the affected person warm and
calm. Initiate artificial respiration if the affected
person is experiencing troubled breathing and administer
oxygen if necessary. If the affected person has
difficulty breathing or cannot breathe, tip head back
and perform mouth to mouth respiration. Consult a
physician.
- Should liquid refrigerant come into contact with the
eyes, rinse eyes thoroughly in water for approximately
15 minutes. Then apply eye drops and consult a doctor
immediately, even if the eyes are not hurting.
- Never put anything in the mouth of an unconscious
person. If the symptoms continue or if ever there is a
concern, seek medical advice.
- The doctor must be informed that the injury was
caused by refrigerant R134a. Should refrigerant come
into contact with other parts of the body despite
compliance with safety regulations, these must likewise
be rinsed immediately for at least 15 minutes with cold
or lukewarm water.
- If contact with eyes or mucous membranes occurs,
immediately rinse with copious amounts of running water
and consult an eye specialist.
- Immediately remove clothing that refrigerant has
contacted and rinse the area of the skin affected with
cold or lukewarm water. Do not use hot water. Seek
medical attention if frostbite occurs.
Note
- The refrigerant has a faintly noticeable odor which is
therefore not perceptible.
- The refrigerant is heavier than air and falls to lower lying
areas such as the work pit, basements, and deep spots and
displaces the breathable air and oxygen. Remaining in oxygen
deprived areas is life endangering.
- Liquid refrigerant for example from a leak evaporates at an
ambient pressure of approximately 1 bar at roughly -29 ºC (84
ºF). If the refrigerant evaporates on skin, it can cause
cryogenic burning. Delicate organs for example the cornea, are
especially at risk. Excessive frostbite may be life threatening.
- The refrigerant breaks down near flames or when it comes in
contact with hot surfaces. There is a danger of becoming
poisoned by the resulting toxic fumes if inhaled. A pungent odor
indicates that the products of the decomposition mentioned above
have already formed. Avoid inhaling these substances under all
circumstances, as otherwise the respiratory system, lungs and
other organs could be damaged.
- The specific dangers associated with the refrigerant,
material data etc. can be found in the safety data sheets.
Never weld or hard/soft solder components of a filled A/C
system. This also applies to welding and soldering on the
vehicle, if there is a risk that it may heat up components in
the A/C system. When performing paintwork repairs, the
temperature in the drying booth or preheating zone must not
exceed 80 ºC (176 ºF).
Reason:
Exposure to heat increases the pressure in the system, which
could cause the pressure relief valve to open.
Corrective Measure:
- Discharge refrigerant circuit using A/C service station.
Note
Always replace damaged or leaking A/C system components. Do
not attempt to repair them by welding or soldering.
Refrigerant reservoirs (for example, charging cylinders on
the A/C service station) must never be subjected to excessive
heat or exposed to direct sunlight.
Corrective Measure:
- Reservoirs must never be completely filled with liquid
refrigerant. Without sufficient room for expansion (gas
cushion), reservoirs will rupture with devastating effects in
the event of a temperature increase. Refer to
→ Chapter "Refrigerant R134a Characteristics".
Refrigerant is never to be transferred to systems or vessels
in which air is present.
Corrective Measure:
- Evacuate systems and reservoirs before charging with
refrigerant.
Refrigerant Circuit, General Precautions
General Information
- Ensure absolute cleanliness when working.
- Wear safety goggles and gloves when working with refrigerant
and nitrogen.
- Workshop extraction systems are to be switched on.
- Use the service station to discharge the refrigerant
circuit, only then open screw connections and replace the
malfunctioning components.
- Use a cap to seal off any opened assemblies and hoses to
prevent moisture and dirt from getting in.
- Make exclusive use of tools and materials intended for
refrigerant R134a.
- Seal opened refrigerant oil containers to guard against
moisture.
Note
- After engine all service work, screw sealing caps (with
seals) onto all connections with valve and service connections.
- Before starting up A/C system. Observe vehicle specific
filling capacities. Refer to
→ Chapter "Refrigerant R134a Capacities, Refrigerant Oil and
Approved Refrigerant Oils".
- Do not fill refrigerant, extract the refrigerant present and
refill the system.
Vehicles with a High Voltage System (Hybrid Vehicles)
Extremely Dangerous Due to High-Voltage
The high-voltage system is under high-voltage. Death or serious
bodily injury by electric shock.
- Individuals with electronic/medical life- and health sustaining
machines in or on their person cannot perform any work on high-voltage
systems. Life- and health sustaining machines are for example pain
killer pumps, implanted defibrillators, pacemakers, insulin pumps, and
hearing aids.
- Have the high-voltage system de-energized by a qualified person.
There is a Risk of Injury from the Engine Starting Unexpectedly
On electric - hybrid vehicles an active ready mode is difficult to
identify. Parts of the body can be clamped or pulled.
- Turn off the ignition.
- Place the ignition key outside of the vehicle interior.
Risk of Damaging the High-Voltage Cables
Misuse can damage the insulation of high-voltage cables or
high-voltage connectors.
- Never support objects on the high-voltage cables and the
high-voltage connectors.
- Never support tools on the high-voltage cables and the high-voltage
connectors.
- Never sharply bend or kink the high-voltage cables.
- When connecting pay attention to the coding of the high-voltage
connectors.
For all procedures on vehicles with high-voltage system pay
attention to the additional warning message for these vehicles.
Refer to
→ Chapter "Warnings when Working on Vehicles with High Voltage
System".
If procedures are necessary near components of the
high-voltage system "perform a visual inspection of the damage
of the high-voltage components and lines". Refer to
→ Chapter "Performing a Visual Inspection of Damage to High
Voltage Components and Cables".
If work on the components of the high-voltage system is
necessity, de-energize the high-voltage system. Refer to
→ Rep. Gr.93; High-Voltage System, De-Energizing or
→ Electrical Equipment; Rep. Gr.93; High-Voltage System,
De-Energizing.
Vehicles with Start/Stop System
There is a Risk of Injury from the Engine Starting Unexpectedly
The engine can start unexpectedly on vehicles with an activated
Start/Stop System. A message appears in the instrument cluster
indicating whether the Start/Stop System is activated.
- Deactivate the Start/Stop System: Turn off the ignition.
All Vehicles
- General Information. Refer to
→ Chapter "General Information".
- Refrigerant Circuit, Cleaning. Refer to
→ Chapter "Refrigerant Circuit, Cleaning".
- Additional notes for vehicles with A/C compressor without
A/C clutch (with A/C Compressor Regulator Valve -N280-). Refer
to
→ Chapter "Additional Information for Vehicles with A/C
Compressor without A/C Clutch, (only with A/C Compressor
Regulator Valve -N280-)".
- O-ring seals. Refer to
→ Chapter "O-Ring Seals".
Refrigerant Circuit, Cleaning
Cleaning the refrigerant circuit with refrigerant R134a
(flushing with refrigerant R134a). Refer to
→ Chapter "Refrigerant Circuit, Cleaning (Flushing), with
Refrigerant R134a". (Or blow out with compressed air
and nitrogen). Refer to
→ Chapter "Refrigerant Circuit, Flushing with Compressed Air and
Nitrogen". In the event of:
- Moisture or dirt has gotten into the refrigerant circuit,
for example, after a crash.
- Refrigerant oil is dark and viscous.
- There is too much refrigerant oil in the refrigerant circuit
after replacing the compressor.
- The A/C compressor had to be replaced due to "internal"
damage (for example, noises or no output).
Note
When flushing components with compressed air and nitrogen,
extract the gas mixture escaping from the components thoroughly
via an existing exhaust-extraction ventilation system (workshop
extraction system).
Additional Information for Vehicles with A/C Compressor without A/C
Clutch, (only with A/C Compressor Regulator Valve -N280-)
- The engine can be started only after the refrigerant circuit
has been completely assembled (the A/C compressor runs
continuously).
- If the engine has to be operated with the refrigerant
circuit empty, only do so for as long as absolutely essential
and avoid high engine speeds.
Additional Information for Vehicles with High Voltage System
Vehicles with a high-voltage system (hybrid vehicles)
Extremely Dangerous Due to High-Voltage
The high-voltage system is under high-voltage. Electrocution can
cause death or very serious personal injury from damages high-voltage
components and high-voltage cables.
- Perform a visual inspection of the high-voltage components and the
high-voltage cables.
- Never use tools that are for cutting, deformed, or sharp edged.
- Never use welding, soldering, thermal adhesive or hot air.
There is a Risk Of Injury from the Engine Starting Unexpectedly
On electric - hybrid vehicles an active ready mode is difficult to
identify. Parts of the body can be clamped or pulled.
- Turn off the ignition.
- Place the ignition key outside of the vehicle interior.
Risk of Damaging the High-Voltage Cables
Misuse can damage the insulation of high-voltage cables or
high-voltage connectors.
- Never support objects on the high-voltage cables and the
high-voltage connectors.
- Never support tools on the high-voltage cables and the high-voltage
connectors.
- Never sharply bend or kink the high-voltage cables.
- When connecting pay attention to the coding of the high-voltage
connectors.
- For all procedures on vehicles with high-voltage system pay
attention to the additional warning message for these vehicles.
Refer to
→ Chapter "Warnings when Working on Vehicles with High Voltage
System".
- Procedures necessary near the components of the high-voltage
system. Refer to
→ Chapter "Performing a Visual Inspection of Damage to High
Voltage Components and Cables" and
→ Rep. Gr.00; Safety Precautions or
→ Electrical Equipment; Rep. Gr.93; High Voltage System General
Warnings.
- Further information about the high-voltage system. Refer to
→ Rep. Gr.00; Safety Precautions or
→ Electrical Equipment; Rep. Gr.93; General Warnings for Working
on High-Voltage System.
- If procedures on components of the high-voltage system are
required, de-energize the high-voltage system. Refer to
→ Rep. Gr.00; Safety Precautions or
→ Electrical Equipment; Rep. Gr.93; High Voltage System General
Warnings.
- The engine may only be started if the refrigerant circuit is
completely assembled.
- Hybrid drive on vehicles with battery cooling is only
possible with a full A/C system in which there are no stored
errors. Use the Vehicle Diagnostic Tester in the "Guided Fault
Finding" function for the A/C system and the battery regulation.
- After the installation of the electrically-driven A/C
compressor and the subsequent filling of the refrigerant
circuit, start the A/C compressor for the first time using the
"compressor intake" function for the basic setting. If the
refrigerant oil was improperly stored before installation in the
A/C compressor compression chamber, the A/C compressor may
become damaged. Use the Vehicle Diagnostic Tester in the "Guided
Fault Finding" function for the A/C system and the battery
regulation.
- Only activate the electrically-driven A/C compressor when
the refrigerant circuit is filled. The A/C compressor may become
damaged if the A/C compressor is run when the refrigerant
circuit is empty. Use the Vehicle Diagnostic Tester in the
"Guided Fault Finding" function for the A/C system and the
battery regulation.
- So that the refrigerant circuit can be emptied, evacuated
and filled depending on the design of the refrigerant circuit
different electric controlled valves must be opened (for example
on the Audi Q7 e-tron). Refer to
→ Heating, Ventilation and Air Conditioning; Rep.
Gr.87; Refrigerant Circuit. Use the Vehicle
Diagnostic Tester in the "Guided Fault Finding" function.
- For checking the A/C function specific electric controlled
valves must be opened or closed (for example on the Audi Q7 e-tron).
Refer to
→ Heating, Ventilation and Air Conditioning; Rep.
Gr.87; Refrigerant Circuit. Use the Vehicle
Diagnostic Tester in the "Guided Fault Finding" function.
- The service connection on the high pressure side depends on
the vehicle, not all operating conditions of the A/C system are
on high pressure (for example on the Audi Q7 e-tron). For this
reason to check the A/C function in these vehicles the sensor
installed in the refrigerant circuit must be used. Refer to
→ Heating, Ventilation and Air Conditioning; Rep.
Gr.87; Refrigerant Circuit. Use the Vehicle
Diagnostic Tester in the "Guided Fault Finding" function.
- 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
→ Electrical Equipment General Information; Rep. Gr.27; Battery,
Charging and
→ High Voltage Vehicle General Information; Rep.
Gr.93; High-Voltage System General Warnings.
- For testing and measurement procedures that require the
ready mode to be active or the ignition to be switched on, the
selector lever must be in the "P" position and the parking brake
must be activated. The required tools must be placed so that
they do not come into contact with any rotating components in
the engine and they must also not go into the vicinity of the
rotating components when the engine is running.
O-Ring Seals
- Make exclusive use of seals which are resistant to
refrigerant R134a and the related refrigerant oils. Color coding
of O-rings is no longer employed. Colored and black O-rings are
used.
- Be sure to use seals with the correct inner diameter. Refer
to the Parts Catalog and
→ Heating, Ventilation and Air Conditioning; Rep. Gr.87; System
Overview - Refrigerant Circuit (vehicle-specific
repair manual).
- The O-rings may be used only one time.
- Coat the seals lightly with refrigerant oil (PAG oil) before
installing.
After Charging A/C System
Mechanically Driven A/C Compressor
After installing the A/C Compressor to the engine (before
positioning the belt or installing the driveshaft) Refer to
→ Chapter "A/C System, Operating after Charging" and
→ Heating, Ventilation and Air Conditioning; Rep. Gr.87; A/C
Compressor.
- Turn the A/C compressor by hand via the clutch plate or belt
pulley on the A/C clutch approximately 10 turns.
After charging. Refer to
→ Chapter "A/C System, Operating after Charging".
- Start the engine with the A/C turned off (A/C Clutch -N25-
and A/C Compressor Regulator Valve -N280- are not actuated).
- Following engine idling speed stabilization, switch on A/C
compressor and run it for at least 10 minutes at idling speed
with maximum cooling output.
Electrically Driven A/C Compressor
- First start the electrically driven A/C compressor after
filling the refrigerant circuit via the "Compressor Cut-In"
function from the basic setting. Refer to
→ Chapter "A/C System, Operating after Charging" and
Vehicle Diagnostic Tester in the "Guided Fault Finding" Function
for the A/C System and the Battery Regulation.
READ NEXT:
Extremely Dangerous Due to High-Voltage
The high-voltage system is under high-voltage. Death or serious
bodily injury by electric shock.
- Individuals with electronic/medical life- and health
Caution
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
SEE MORE:
If you must drive through water, follow these instructions:
Check the stability of the ground, the current,
and the water depth. If the ground is unstable,
there is a strong current, or there are waves,
the water must only reach up to the lower edge
of the body at the most.
Deactivate the Sta
Procedure
The requirements for testing the cooling capacity are
fulfilled. Refer to
→ Chapter "A/C Cooling Output, Testing Requirements".
- Measure the ambient temperature (must be warmer than 15 ºC
(59 ºF) ).
- Close the doors, the engine hood, the windows, the sunr