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:

• If liquid refrigerant enters the eye, do not rub it. Gently run large quantities of eye wash over affected eye to raise the temperature. If an eye wash is not available, cool, clean water may be used to flush the eye. After rinsing, cover the eye with a clean pad and seek immediate medical attention.
• If liquid refrigerant is splashed onto the skin, run large quantities of water over the affected area to raise the temperature. Implement the same action if the skin comes in contact with discharging cylinders. Wrap the contaminated body parts in blankets (or similar materials) and seek immediate medical attention.

Observe the following precautions when handling components used in the air conditioning system:

• Air conditioning units must not be lifted by their hoses, pipes or capillary lines.
• Hoses and lines must not be subjected to any twist or stress; the efficiency of the system will be impaired by kinks or restrictions. Ensure that hoses are correctly positioned before tightening couplings, and ensure that all clips and supports are utilized.
• Completed assemblies must be checked for refrigeration lines touching metal panels. Any direct contact of components and panels may transmit noise and so must be eliminated.
• The appropriate torque wrench must be used when tightening refrigerant connections to the stipulated value. An additional wrench must be used to hold the union to prevent twisting of the pipe when tightening connections.
• All protective plugs must remain in place to seal the component until immediately prior to connection.
• Ensure components are at room temperature before uncapping, to prevent condensation of moisture from the air that enters it.
• Components must not remain uncapped for longer than 15 minutes. In the event of a delay, the caps must be fitted.
• When disconnecting, immediately cap all air conditioning pipes to prevent ingress of dirt and moisture into the system.
• The receiver/drier contains desiccant which absorbs moisture. It must be positively sealed at all times. A receiver/drier that has been left uncapped must not be used.
• The receiver/drier should be the last component connected to the system to ensure optimum dehydration and maximum moisture protection of the system.
• Use alcohol and a clean, lint-free cloth to clean dirty connections.
• Ensure that all new parts fitted are suitable for use with the specified refrigerant.

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.

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.