EV thermal management: A service opportunity you can’t afford to ignore
7 September 2026 
As the number of EVs on our roads increases, demand for servicing thermal management systems will rise. Refrigerant gas specialist, Orbia Fluor and Energy Materials, explains how independent workshops can take advantage of this revenue opportunity.
EVs now account for around one in four new car sales globally and 28% of the European market. Thermal management is therefore becoming far more important than simply maintaining cabin comfort during summer journeys. In modern vehicles, particularly EVs and hybrids, dedicated refrigerant circuits or refrigerant-to-coolant heat exchangers that work in conjunction with the HVAC system are increasingly used to remove heat from the battery pack and power electronics, helping to keep key components operating within their intended temperature range and, in turn, maintaining vehicle performance and supporting efficiency.
So, as the role of thermal management in the vehicle evolves, it is becoming a higher-value service area. Plus, it has moved from a seasonal maintenance task to an important part of the vehicle lifecycle and an increasingly routine element of general servicing.
To tap into this potential revenue stream, workshops are encouraged to invest in technician training so teams understand the latest vehicle thermal-management systems and refrigerant technologies. Technicians should also ensure that their servicing equipment is suitable for modern A/C and heat-pump architectures and compatible with newer refrigerants. And finally, keeping pace with F-gas and OEM developments will be increasingly important so that the workshop can advise customers confidently.
New refrigerants provide new opportunities
There is a further opportunity for workshops in thermal management arising from changes to the refrigerants used in modern vehicles.
Automotive air-conditioning is undergoing a major shift across Europe as legacy refrigerant R-134a is being phased down due to its high global warming potential (GWP).
The industry has already shifted to R-1234yf in newer vehicles, as manufacturers have redesigned systems to compensate for performance losses and address the transition from a non-flammable refrigerant (A1) to a mildly flammable one (A2L).
However, technicians throughout Europe are experiencing rising costs for R-1234yf because of heightened demand and supply chain challenges. Environmentalists have also raised concerns about its high TFA (Trifluoroacetic Acid) yield.
So, technicians need practical, economical, and reliable alternatives that keep all vehicles compliant and operational.
One viable alternative is Klea Edge 444A (R-444A), which has been developed by Orbia Fluor and Energy Materials as a more economic, direct replacement for R-1234yf. It is fully compatible with existing R-1234yf systems and oils, shares the same flammability classifications (A2L) and generates much less TFA.
Independent testing has shown that R-444A can deliver faster cooling and comfort than R-1234yf. In EVs, improved cooling performance can support vehicle efficiency and charging performance, and increase range.
For vehicles that have already adopted R-1234yf, R-444A offers a direct alternative.
Testing shows the cabin cool-down times are noticeably faster than R-1234yf, without requiring system modifications. The refrigerant itself is designed to deliver this performance using R-1234ze(E), R-32 and R-152a, giving technicians another option that balances performance with operating costs for consumers.
Practicalities of retrofitting R-444A
R-444A can be charged using the same procedure as R-1234yf, as it shares the same flammability classifications, reducing complexity in day-to-day workshop operations.
Retrofitting should start with a full vehicle inspection: confirming the existing refrigerant in the system, checking hoses, seals and compressor condition, looking for leaks, and assessing the oil.
When retrofitting, oil compatibility is critical. Contaminated or incompatible oil should be replaced, with the system flushed, if necessary, particularly if there is compressor failure. Matching the correct oil type and viscosity ensures optimal compressor performance and longevity. Oil compatibility with existing R-1234yf lubricants further simplifies servicing, though technicians should continue to check manufacturer guidance.
Technicians can charge the system with R-444A by weight, extracting liquid from a virgin container to maintain the blend composition. The typical charge is the same as the original R-1234yf specification, ensuring both performance and compliance.
Once the system is charged, the A/C can be turned to max to check high and low-side pressures, compressor operation, and ensure the vent temperatures meet specification.
The final stage of retrofitting should include recording and displaying all details of the retrofit – refrigerant type, oil type, charge weight, technician, and date, protecting technicians and vehicle owners in future servicing.
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