General Repair Information

General Repair Information

• A data plate in engine compartment indicates the refrigerant used and capacity.

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.

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.

How to handle high voltage cable:

• 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.

• Color-code the round high voltage connector with an external color ring and code them mechanically using the guide- or code tabs. Always make certain that the coding matches when connecting the round connector in order to avoid mechanically damaging 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 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 the cover 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 causing 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 is deactivated (ignition switched off) whenever working on the vehicle.

All vehicles

Before working on electrical system (wiring), remove relevant fuse(s).

• Disconnect the battery (A) , the auxiliary battery (A1) and the traction battery (A2) before starting any electric welding on the vehicle.

The A/C refrigerant system may be drained and opened only if it is for safety reasons, refer to => [ A/C and Refrigerant Safety Precautions ] A/C and Refrigerant Safety Precautions or if components of the A/C refrigerant system must be replaced, refer to => [ Refrigerant Circuit Draining ] Refrigerant Circuit Draining.

When performing all other usual vehicle repair work, the refrigerant circuit of the A/C system should remain closed.

Repairs to the heating and A/C without opening the refrigerant circuit are possible and are described in => [ Refrigerant Circuit Component Overview ] Refrigerant Circuit Component Overview or => [ Refrigerant Circuit Component Overview ] Refrigerant Circuit Component Overview, => [ A/C System Control and Regulation Components Outside Passenger Compartment ] A/C System Control and Regulation Components Outside Passenger Compartment and => [ A/C System Control and Regulation Components Inside Passenger Compartment ] A/C System Control and Regulation Components Inside Passenger Compartment.

• The connections for the senders/switches described in this Workshop Manual are fitted with a valve which closes automatically when the switches are unscrewed. These switches can thus be replaced in any Audi and Volkswagen workshop even though the refrigerant circuit is fully charged.

Service work on the A/C system that requires the refrigerant circuit to be discharged and thus cannot be performed in every Audi and Volkswagen workshop are described in=> [ Refrigerant Circuit, Servicing ] Refrigerant Circuit, Servicing. Certain tools are required to discharge the refrigerant circuit. These work procedures must only be performed by trained personnel as well. Therefore, bring vehicle to a workshop that has the necessary tools and in which the work can be performed accordingly by qualified personnel if necessary.

• Contact corrosion, refer to => [ Contact Corrosion ] Contact Corrosion.

• A/C components controlled or activated by other control modules, electrical tests, refer to => [ A/C Components Controlled or Activated by Other Control Modules, Electrical Tests ] Testing and Inspection.

• Components actuated by A/C system, electrical test, refer to => [ Components Actuated by A/C System, Electrical Test ] Components Actuated By A/C System, Electrical Test.