The air conditioning system contains fluids and components which could be potentially hazardous to the technician or the environment if not serviced and handled correctly. The following guidelines are intended to alert the technician to potential sources of danger and emphasize the importance of ensuring the integrity of the air conditioning operating conditions and components fitted to the vehicle.
Where necessary, additional specific precautions are detailed in the relevant sections of this Manual which should be referred to prior to commencing repair operations.
The refrigerant used in the air conditioning system is R134a or R1234yf.
If an accident involving refrigerant should occur, conduct the following remedial actions:
Observe the following precautions when handling components used in the air conditioning system:
Always carry out the following procedure before connecting any hose or pipe:
Use the HVAC machine to perform a leak test after a major repair has been completed.
The compressor contains a lubricant, which has greater electrical insulating properties than the A/C lubrication oil normally used for standard mechanical belt driven A/C pumps. It is important that the compressor is kept upright at all times to retain the lubricant in the compressor’s sump.
A new compressor is sealed. Ensure that no foreign material is allowed to enter the compressor.
If the air conditioning system is involved in accident damage and the system is punctured, the refrigerant will discharge rapidly. The rapid discharge of refrigerant will also result in the loss of most of the oil from the system. The compressor must be removed and all the remaining oil in the compressor drained and refilled as instructed in the air conditioning section of this manual.
The HVAC and battery coolant circuits are sealed to prevent the discharge of refrigerant. The refrigerant must be recovered before any removal of system components using the recommended equipment.
Two ports are provided on the HVAC system and are accessible under the hood.
This port is fitted onto the pipe directing the high pressure refrigerant gas from the compressor to the condenser. It can be accessed under hood from the RH side of the vehicle adjacent to the RH suspension shock tower strut brace. A Schraeder valve forms the port in the pipe allowing the connection of charging/discharging equipment for servicing purposes. The connection is a 16 mm quick coupler. The valve is fitted with a screw-on cap to prevent seepage of refrigerant through the valve and also to exclude dirt.
This pipe leads back from the evaporator. It can be accessed under hood, from the RH side of the vehicle adjacent to the HP Schraeder valve. It forms a port at the top of the pipe which allows the connection of recovery/charging equipment for servicing purposes. The connection is a 13mm quick coupler. The valve is fitted with a screw-on cap to prevent seepage of refrigerant through the valve and also to exclude dirt.
The vehicle uses two separate circuits, one circuit for the evaporator situated in the HVAC assembly for the cabin environment, and an additional circuit for the battery heat exchanger.
Both of these circuits have solenoid valves controlled by the thermal controller module. During A/C evacuation and recharge it is important to open these solenoids manually (service mode). This will ensure that all refrigerant is removed and replaced from both circuits during evacuating and recharge of the system.
With the vehicle in service mode, the refrigerant can be recovered or recharged. The HVAC system will stay in service mode until the mode is exited using Toolbox or the laptop is disconnected from the vehicle.
Internally or externally damaged components can cause debris and moisture to enter the A/C system. Perform the following procedures if debris or excessive moisture ingress is suspected.
When the air conditioning system is discharged/recharged, any existing refrigerant is recovered from the system and recycled. The system is then charged with the required weight of refrigerant and new oil equal in volume to the oil recovered.