General Information
Note
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
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-)
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.
- 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
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.