Hybrid/Electric Automotive HVAC Systems

   Hybrid/Electric (HEVs) A/C System Service Precautions:

1. NEVER FLUSH AN HEV SYSTEM, NEVER NEVER NEVER, as it can damage the system and lead to expensive battery failure. Similarly, using the wrong oil or contaminated charging equipment can have the same detrimental effects.
2. Use dedicated equipment (recharge machine, gauges, etc.) for HEV systems.

        • HEV A/C compressors require Polyol Ester (POE) oil, a non-conductive oil                with high dielectric properties.
        • DO NOT USE STANDARD PAG OIL! Even trace amounts of PAG oil in                        recharge hoses can short the system and cause a battery failure code. PAG oil            is hygroscopic (attracts moisture) and can break down the insulating properties            of windings on the electric motor. The windings are intended to be coated with              POE oil in order to protect the insulation on the windings and prevent electrical            leakage.
        • DO NOT USE OIL-BASED FLORESCENT LEAK DETECTION DYE - Like                    refrigerant oil, HEV systems require POE oil based leak detection dye. Non-                  HEV leak detection dye is manufactured with PAG oil, which can cause the                    same detrimental effects of using PAG refrigerant oil. Before adding leak                      detection dye, verify if the vehicle was manufactured with dye in the system                  (not necessary to add more) or if the system was recently repaired (removing                components with dye).
     3.  HEVs WITH BELT DRIVEN ONLY SYSTEMS, can be repaired like other belt-              driven systems.
     4.  HEVs WITH ELECTRIC COMPRESSORS REQUIRE A DIFFERENT                              APPROACH:
         • Compressor with large orange cable indicates a high-voltage system.
         • Take the time to review and refer to manufacturer’s service specifications.
         • Power down the electrical system per manufacturer’s specifications.
         • Use lineman's gloves to disconnect the orange cable.

HEV ELECTRIC COMPRESSORS are designed with a spirally wound, fixed scroll and variable scroll with a brushless motor. These systems require high insulation for compressor lubrication, featuring a wet sump lubrication system where the armature is submerged in oil for optimal lubrication and cooling performance.
     • HEV SCROLL COMPRESSORS can be powered via belt when engine is running,         or electrically when the engine is off. Common on 2001-2003 Honda and Toyota           Prius models.
    • HEV INVERTER COMPRESSORS are high-voltage electric motors. These                    operate independently of the engine and rely on high-voltage AC supplied by the          A/C inverter. Common on late model hybrid vehicles.

8011275 • R134a Hybrid Oil

8011307 • R1234yf Hybrid Oil

It's essential to understand the unique requirements of hybrid A/C systems and adhere to manufacturer guidelines to avoid potential issues and costly repairs.
Remember these dos and don'ts when working with hybrid A/C systems:

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