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.

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