Get Checkingpressuresonvehicles -> 10.1 Checking pressures in refrigerant circuit... Guide for Volkswagen LT Van Second Generation (1996-2006)

Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...

Air conditioning system with refrigerant R134a - Edition 10.2014

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver

conditioner com‐

pressor and for

air conditioner

compressor itself

tioner

unit -

N541-

and in‐

stall

shut-off

lk

tap -

VAS

6338/4

2- .

Comply

with

notes

⇒

pa

ge

121 .

– If no

shut-off

tap -

VAS

6338/4

2- is

availa‐

ble, a

voltage

of 12 V

may be

applied

to shut-

off

valves -

N541-

and -

N542-

as an

alterna‐

tive.

7. Clearing refrigerant circuit of contaminants

117

Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...

Air conditioning system with refrigerant R134a - Edition 10.2014

e-Golf 2014 and e-Golf 2014 with heat pump

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver

conditioner com‐

pressor and for

air conditioner

compressor itself

e-Golf

♦ Low-pres‐

sure side

adapter -

VAS

– Remove dryer car‐ – Install

2014 ►

tridge and seal re‐

ceiver.

adapter

- VAS

6338/3

4- in

6338/12-

– After flushing, in‐

stall a new dryer

cartridge.

place of

expan‐

sion

♦ High-pres‐

sure side

adapter -

valve

(or a

VAS 6338/3-

drilled

out ex‐

pan‐

♦ Purging elec‐

trical air con‐

ditioner com‐

pressor,

sion

valve

⇒

adapter -

VAS

pa

6338/40- and

Adapter -

VAS

lk

ge 71 )

– After

6338/41- ,

Observe

purg‐

ing, in‐

stall a

new ex‐

pan‐

notes:

⇒ page 82

sion

valve.

118

Rep. gr.00 - Technical data

lk

Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...

Air conditioning system with refrigerant R134a - Edition 10.2014

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver

conditioner com‐

pressor and for

air conditioner

compressor itself

e-Golf

2014 ►

with

♦ Low-pres‐

sure side

adapter -

VAS

– Remove reservoir – Start

(dryer), and bridge

refrigerant pipes.

“Basic

setting”

in ⇒ Ve‐

hicle di‐

agnos‐

tic test‐

er, and

start

heat

pump

6338/12-

– Join two adapters -

VAS 6338/6- and

connect to hose -

VAS 6338/31- .

♦ High-pres‐

sure side

adapter -

VAS 6338/3-

– After flushing, in‐

stall a new reser‐

voir.

the

func‐

♦ Purging elec‐

trical air con‐

ditioner com‐

pressor,

tion

“Charg

e refrig‐

erant

adapter -

VAS

circuit”.

♦ This will

open

6338/40- and

Adapter -

VAS

the

electri‐

cal

6338/41- ,

Observe

valves

in the

notes:

⇒ page 82

refrig‐

erant

circuit.

♦ Leave

vehicle

diag‐

nostic

tester

con‐

nected

to keep

the

valves

open.

7. Clearing refrigerant circuit of contaminants

119

Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...

Air conditioning system with refrigerant R134a - Edition 10.2014

Golf Hybrid 2014

Vehicle Adapters re‐

Adapters requir^l^ked for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver

conditioner com‐

pressor and for

air conditioner

compressor itself

Golf Hy‐ ♦ Low-pres‐

There are two versions ♦ Install

brid

sure side

adapter -

VAS

of the fluid receiver:

See vehicle specific re‐

pair manual.

adapter -

2014 ►

VAS

6338/38-

in place of

expan‐

6338/12-

♦ Fluid receiver with

permanently fitted

dryer

♦ High-pres‐

sure side

sion valve

(or a dril‐

led out ex‐

pansion

valve

adapter -

– Can be flushed

through.

VAS 6338/3-

– After flushing, in‐

stall a new receiver.

♦ Receiver with des‐

iccant bag or car‐

tridge

♦ Purging elec‐

trical air con‐

ditioner com‐

pressor,

⇒

page 71 )

♦ Replace

shut-off

valves -

N541-

adapter -

VAS

– Remove desiccant

bag/cartridge and

seal fluid receiver.

6338/40- and

Adapter -

VAS

and -

N542-

6338/41- ,

Observe

– After purging, in‐

stall a new desic‐

cant bag/cartridge.

with two

shut-off

taps -

notes:

⇒ page 82

VAS

6338/42- .

Comply

with notes

⇒

page

121 .

♦ Remove

restrictor

in refriger‐

ant line to

heat ex‐

changer

for high-

voltage

battery,

and drill it

out (see

notes be‐

low)

⇒

page

121 .

120

Rep. gr.00 - Technical data

Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...

Air conditioning system with refrigerant R134a - Edition 10.2014

Note

In the Golf Hybrid 2014, the refrigerant circuit is flushed in 2 cy‐

cles. For the first cycle, the adapter for the shut-off valve -N541-

is open, and the adapter for shut-off valve -N542- is closed. This

will cause the refrigerant circuit with the evaporator in the heater

and air conditioning unit to be flushed. For the second cycle, the

lk

adapter for the shut-off valve -N541- is closed, and the adapter

for shut-off valve -N542- is open. This will cause the refrigerant

circuit with the evaporator in the heat exchanger for high-voltage

battery to be flushed ⇒ Heating, air conditioning; Rep. Gr. 87;

Refrigerant circuit; System overview - refrigerant circuit (repair

manual for the specific vehicle).

Note

♦ The illustration shows a refrigerant line -A- with a permanently

installed restrictor -B- (without strainer). This refrigerant line

must be drilled open with a suitable 5 mm drill bit (remove the

restrictor if it is removable), and it must be cleaned before it is

installed in the purging circuit. Renew the refrigerant line which

has been drilled open after purging has been completed ⇒

Electronic Parts Catalogue .

♦ The diameter of the shown restrictor hole -B- is

approx. 0.7 mm. Depending on the refrigerant line version, this

restrictor is permanently installed or it can be removed. For the

removable version a strainer may be fitted to prevent the re‐

strictor hole from being blocked by suspended particles.

7. Clearing refrigerant circuit of contaminants

121

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Air conditioning system with refrigerant R134a - Edition 10.2014

8

Complaints

8.1

Possible complaints about refrigerant

circuit

Note

lk

♦ The air conditioning system is operating correctly if the air

emerging from the vent on the dashboard is at a temperature

o

of 7 C or less.

♦ Set the Climatronic to: “LO”.

♦ Set the air conditioning system: “AC” on; “max”; “cold”.

8.1.1

Test prerequisites:

•

Self-diagnosis of the air conditioning system with the Vehicle

diagnosis, testing and information system - VAS 5051A- using

“Guided Fault Finding” cannot detect any faults; no switch-off

conditions for the air conditioner compressor are set in the

measured value block (only when the vehicle “air conditioning

system” is fitted with self-diagnosis).

⇒ Rep. gr. 87

8.1.2

Possible complaints

Note

For all complaints marked with a * ⇒ page 127 .

♦ The cooling has failed completely. *

♦ Insufficient cooling at all vehicle speeds and engine speeds.*

♦ No cooling or insufficient cooling after a distance of several

kilometres has been driven. *

♦ The air conditioner compressor, the air conditioning system

magnetic clutch - N25- or the air conditioner compressor reg‐

ulating valve - N280- have been switched off by low-pressure

switch for magnetic clutch - F73- , high-pressure switch for

magnetic clutch - F118- , air conditioning system pressure

switch - F129- or by operating and display unit for Climatronic

air conditioning system - E87- or Climatronic control unit -

J255- because pressure was too high or too low.* *

♦ No fresh air flow, or very much reduced fresh air flow after

driving some distance (evaporator iced up). *

In addition the following complaints may also arise:

The air conditioner compressor is noisy

– Tighten the securing screws for the air conditioner compressor

and the air conditioner compressor bracket using a torque

wrench.

– Check routing of refrigerant pipes; they must not touch other

components and must be installed without tension (adjust if

necessary).

122

Rep. gr.00 - Technical data

Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...

Air conditioning system with refrigerant R134a - Edition 10.2014

Noises (refrigerant hammering) occur immediately after the air

conditioning is switched on and/or in a curve or when the brakes

are applied:

– Discharge refrigerant circuit, evacuate and charge again (too

much refrigerant in circuit).

Note

♦ Excess refrigerant oil in the circuit may also cause this problem

(e.g. if the refrigerant oil level was not checked after the air

lk

conditioner compressor was renewed). In case of this com‐

plaint, the refrigerant circuit must be purged with R134a re‐

frigerant ⇒ page 67 .

♦ The refrigerant must be drained from the air conditioning com‐

pressor. To facilitate this process, turn the air conditioner

compressor over by hand at the poly V-belt pulley or coupling

disc of the magnetic coupling. Then fill refrigerant circuit with

total amount of refrigerant oil (50 g direct into air conditioner

compressor) according to ⇒ vehicle-specific workshop man‐

ual .

Water sprays out of the air vents (dash panel or footwell) although

the air conditioning system otherwise works properly:

– Check that the condensation water drain is properly routed; it

must not be pinched or kinked.

– The condensed water drain valve must not be hindered in its

operation by wax or underbody sealant and must open and

close properly.

– Check the plenum chamber cover; it must be undamaged and

be installed correctly (no water must flow into the evaporator).

– Check water drains in plenum chamber; they must not be

blocked (e.g. by leaves).

8.2

Smells from heater and air conditioner

unit

8.2.1

Is the smell coming from evaporator or

the heat exchanger?

♦ Fishy smell

– Due to leak in engine's cooling system or in heat exchanger of

heater and air conditioner unit.

Note

If the fishy smell is weaker when the temperature is set to “cold”

or stronger when the temperature is set to “warm”, check the heat

exchanger for leaks.

♦ Smell of a burnt clutch

♦ Vapours from foot mats, retrospectively installed seat covers

etc.

♦ Putrid, mouldy smell

– Due to accumulation of leaves, pine needles etc. in plenum

chamber.

8. Complaints

123

Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...

Air conditioning system with refrigerant R134a - Edition 10.2014

Note

Clean plenum chamber.

lk

– Use water so that it cannot flow out of plenum chamber.

Note

Check water runoff points in plenum chamber.

♦ Smell from heater and air conditioner unit

Note

Smells that can originate in heater and air conditioner unit can be

detected in fresh air mode and in recirculation mode.

– Due to too much condensation water in heater and air condi‐

tioner unit

Note

Check the runoff points of condensation water ⇒ Rep. gr. 87 as

indicated in the vehicle-specific repair manual.

– Due to an old or very dirty dust and pollen filter

Note

Check the dust and pollen filter ⇒ Rep. gr. 80 as indicated in the

vehicle-specific repair manual.

– Due to deposits on the fins of the evaporator

Note

Clean the evaporator, using the ultrasonic air conditioner cleaning

unit - VAS 6189A- ⇒ page 124 or the suction feed spray-gun -

V.A.G 1538- and corresponding spray lance ⇒ page 125 .

8.2.2

Ultrasonic air conditioner cleaning unit -

VAS 6189A-

– The ultrasonic air conditioner cleaning unit - VAS 6189A- must

be placed in the front-passenger footwell and sprays the agent

Aero-Clean. Aero-Clean neutralises microbes and bacteria in

the heater and air conditioner unit.

The device is provided with instructions for use.

Current equipment ⇒ ServiceNet; Workshop Equipment; Cata‐

logue; Workshop equipment; Air conditioning/heating; Service

equipment

124

Rep. gr.00 - Technical data

Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...

Air conditioning system with refrigerant R134a - Edition 10.2014

8.2.3

Spraying the evaporator with the suction

feed spray-gun - V.A.G 1538- and spray

lance

Spray the evaporator with Contra Sept directly using a spray

lance (approx. 10 bar). Contra Sept neutralises microbes and

bacteria directly at the evaporator.

In order to enable access to the evaporator, some preliminary

work and different spray lances are necessary, e.g. V.A.G 1538/5;

V.A.G 1538/6 or V.A.G 1538/7.

Vehicle-specific instructions for user are provided with the evap‐

orator cleaning solution D 600 100 A2.

Current equipment and spray lances ⇒ ServiceNet Function

“Search”

lk

8. Complaints

125

Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...

Air conditioning system with refrigerant R134a - Edition 10.2014

lk

9

Connecting air conditioner service

station

9.1

For vehicles that have connections on

both low-pressure and high-pressure

sides of refrigerant circuit

9.1.1

Connecting air conditioner service sta‐

tion for measuring and checking

– Switch off ignition.

– Connect air conditioner service station to power supply.

– Connect quick-release coupling adapters to charging hoses

for air conditioner service station (handwheels not turned in‐

wards, i.e. hand shut-off valves not open).

– Switch on air conditioner service station and evacuate charg‐

ing hoses (necessary only if there is air in the charging hoses).

– Switch off air conditioner service station.

– Unscrew sealing caps from service connections (with valve).

– Connect air conditioner service station via service connections

to the vehicle refrigerant circuit using quick-release coupling

adapter.

– Turn handwheel of quick-release coupling adapter inwards

only far enough to ensure that valves on service connections

are open (check using a pressure gauge; do not overstress

valves).

– Perform the intended measuring and checking work.

126

Rep. gr.00 - Technical data

Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...

Air conditioning system with refrigerant R134a - Edition 10.2014

10

Checking pressures on vehicles

10.1

Checking pressures in refrigerant circuit

(using air conditioner service station)

lk

Note

♦ Check the cooling performance. The air conditioning system

is operating correctly if the air emerging from the vent on the

o

dashboard is at a temperature of 7 C or less.

♦ Set the Climatronic to: “LO”.

♦ Set the air conditioning system: “AC” on; “max”; “cold”.

♦ Connections with valve and service connections for measuring

and testing.

10.1.1

Test prerequisites

•

Radiator and condenser must be clean (clean them if neces‐

sary).

The heat insulation on expansion valve is OK and properly

installed. See vehicle-specific repair manual ⇒ Rep. gr. 87 .

The poly V-belt is OK and properly tensioned. The V-belt for

air conditioner compressor and alternator is in good condition

and correctly tensioned. See vehicle-specific repair manual ⇒

Rep. gr. 87

•

All air ducts, covers and seals are OK and properly installed.

Fault-finding on the electrical systems and vacuum system

has found no faults. See vehicle-specific repair manual ⇒ Rep.

gr. 87

•

Self-diagnosis of the air conditioning system with the vehicle

diagnosis, testing and information system - VAS 5051A- using

“guided fault finding” cannot detect any faults; no switch-off

conditions for the air conditioner compressor are set in the

measured value block (only when the vehicle “air conditioning

system” is fitted with self-diagnosis).

•

The passage of air through the dust and pollen filter is not im‐

paired by dirt. See vehicle-specific repair manual ⇒ Rep. gr.

87

The heater and air conditioner does not draw any secondary

air at highest fresh air blower speed. The evaporator and heat‐

ing do not draw any uncooled air at highest fresh air blower

speed. See vehicle-specific repair manual ⇒ Rep. gr. 87

•

The air duct flaps in the heater and air conditioner reach their

stop positions. See vehicle-specific repair manual ⇒ Rep. gr.

87

The fresh air intake ducts under the bonnet and in the pas‐

senger compartment and their water drain valves are in good

condition. See vehicle-specific repair manual ⇒ Rep. gr. 87

•

The engine is at operating temperature.

The vehicle is not exposed to direct sunlight.

The ambient temperature is higher than 15°C.

All dash panel air vents are open.

10. Checking pressures on vehicles

127

Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...

Air conditioning system with refrigerant R134a - Edition 10.2014

•

With engine running and air conditioning set for maximum

cooling output:

⇒ Rep. gr. 87

Setting maximum cooling output

Settings on operating and display unit for Climatronic air condi‐

tioning system - E87-

– Select “Auto” mode (air conditioner compressor switched on).

– Select temperature setting “LO” for driver and front passenger.

Settings on heater controls:

– A/C button and Rec or recirculate _lb_kuttons should be pressed.

– Set rotary temperature switch to “Cold” stop.

– Set rotary fresh air blower switch to “4”.

•

The radiator fan(s) should be running radiator fan - V7- (at

least at speed 1).*

Note

In some versions, the fan is not switched on until the pressure in

the refrigerant circuit has exceeded a specified value.

•

The fresh air blower - V2- should be running at maximum

speed.

The air flap for fresh air and air recirculation moves to the “re‐

circulation” position or the air flow flap closes and the recircu‐

lation flap opens (within 1 minute of starting the vehicle).

•

The coolant shut-off valve is closed. *

The valves for the pump valve unit are closed (and the coolant

circulation pump is not pumping).*

10.1.2

Checking pressures

– Switch off ignition.

– Connecting air conditioner service station ⇒ page 126 .

– Read pressure from pressure gauges; two results may be dis‐

played.

Ambient temperature (in de‐ Pressure in the refrigerant cir‐

grees centigrade)

+15℃

cuit in bar positive pressure

3.9

4.7

5.6

6.7

7.8

9.1

10.5

+20 ℃

+25℃

+30 ℃

+35℃

+40 ℃

+45℃

128

Rep. gr.00 - Technical data

Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...

Air conditioning system with refrigerant R134a - Edition 10.2014

Note

♦ The temperature of the components of the refrigerant circuit

should be the same as the ambient temperature.

♦ If individual components of the refrigerant circuit are warmer

or colder, then the pressure will deviate from the values shown

in the tables.

♦ Absolute pressure means that 0 bar corresponds to an abso‐

lute vacuum. The normal ambient pressure (positive pressure)

corresponds to 1 bar absolute pressure. On most pressure

gauges, a reading of 0 bar corresponds to an absolute pres‐

sure of one bar (which is confirmed by the existence of - 1 bar

marking beneath the 0 scale marking).

♦ Where vehicles have a high-pressure sender - G65- which in‐

dicates the measured pressure in_lt_khe measured values block,

the measured pressure should agree with the values in the

tables.

⇒ Rep. gr. 87

The pressure in the refrigerant circuit is lower than indicated in

the table

Insufficient refrigerant in circuit.

– Check for leaks in the refrigerant circuit ⇒ page 58 .

– Check the high-pressure safety valve.

If the high-pressure safety valve has blown off:

– Check activation of radiator fan.

– Check refrigerant pipes and refrigerant hoses for restrictions

in cross-section at bends that have too tight radius.

– Check refrigerant pipes and refrigerant hoses for external

damage.

– If no defects are found, blow through refrigerant circuit with

compressed air and nitrogen.

The pressure in the refrigerant circuit is equal to or greater than

that in the table

– Start engine.

– On vehicles with electrical air conditioner compressor, switch

off ignition.

WARNING

High voltage on high-voltage system of hybrid vehicle. Danger

of electric shock! Before starting work, carry out a visual check

of high-voltage components in area of work. Comply with gen‐

eral warnings ⇒ Hybrid electrical system; Rep. gr. 93 ; General

warnings for working on the high-voltage onboard power sup‐

ply system .

– Set air conditioning system for maximum cooling output.

10. Checking pressures on vehicles

129

Checkingpressuresonvehicles -> 10.1 Checking pressures in refrigerant circuit... for Your Volkswagen LT Van Second Generation (1996-2006)

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