1996-2006 Volkswagen LT Van Clearingrefrigerantcircuitofcontaminants User Manual
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Clearingrefrigerantcircuitofcontaminants for Your Volkswagen LT Van Second Generation (1996-2006)

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Air conditioning system with refrigerant R134a - Edition 10.2014  
7
Clearing refrigerant circuit of contam‐  
inants  
7.1  
Blowing through refrigerant circuit with  
compressed air and nitrogen  
•
•
Use compressed air to force moisture and other contaminants  
out of the refrigerant circuit and use nitrogen to force moisture  
out of the refrigerant circuit.  
The method of blowing through the refrigerant circuit with  
compressed air and nitrogen often requires a lot more work  
than purging with refrigerant R134a. When purging with re‐  
frigerant R134a, cleaning of the components is considerably  
better. It is therefore always best to purge the system in the  
event of complaints (the method of blowing through should  
only be selected for certain complaints and for individual com‐  
ponents).  
Only individual components are to be blown through if:  
♦ There is no way of purging the refrigerant circuit with refriger‐  
ant R134a.  
♦ If there is dirt or contamination in individual components of the  
refrigerant circuit.  
♦ If during evacuation of a leak-tight refrigerant circuit the vac‐  
uum display is not constant on gauge (moisture in the refrig‐  
erant circuit, which generates vapour pressure).lk  
♦ If the refrigerant circuit has been left open for longer than nor‐  
mally required for repairs (e.g. following an accident)  
♦ Pressure and temperature measurements in the circuit indi‐  
cate that there is moisture in the refrigerant circuit.  
♦ The vehicle-specific repair manual ⇒ Heating, air conditioning  
deems it necessary after replacement of certain components.  
Note  
♦ Blowing through the refrigerant circuit with compressed air and  
nitrogen will not achieve the same degree of cleanliness as  
purging with refrigerant R134a. When purging with refrigerant  
R134a, the refrigerant oil is shifted and cleaning of the com‐  
ponents is better ⇒ page 67 .  
♦ When blowing through, a maximum working pressure of 15 bar  
must not be exceeded (if necessary, use pressure limiter for  
compressed air as well).  
WARNING  
♦ Nitrogen can escape from the bottle in an uncontrolled  
way.  
♦ Work only with pressure regulator for nitrogen bottles  
(max. working pressure 15 bar).  
♦ The gas mixture escaping from the components must be  
collected with appropriate extraction equipment.  
7. Clearing refrigerant circuit of contaminants  
65  
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– Always blow through components opposite the direction of re‐  
frigerant flow.  
Compressed air and nitrogen cannot be blown through the re‐  
strictor, expansion valve, air conditioner compressor, receiver or  
reservoir.  
– In cases where condensers have a drying agent cartridge in  
the integrated receiver, this drying agent cartridge must be re‐  
moved.  
– First blow out soiling using compressed air and then dry com‐  
ponents with nitrogen.  
– Fit adapter for connection of pressure hose to refrigerant cir‐  
cuit ⇒ page 86 and ⇒ Heating, air conditioning .  
To prevent oil and moisture from the compressed air system  
making its way into the refrigerant circuit, the following points must  
be observed.  
♦ The compressed air must be fed through a compressed air  
cleaning unit to clean and dry it. Therefore, use compressed  
air filter and dryer (included in items supplied with tools for  
painting work) ⇒ Workshop equipment and Special tools cata‐  
logue .  
lk  
♦ If refrigerant pipes have threads or union nuts at connections,  
use adapter - V.A.G 1785/1- to adapter - V.A.G 1785/8- to  
connect to 5/8" - 18 UNF charging hose. These adapters can  
be found in the adapter case for VW/Audi passenger vehicle  
set - VAS 6338/1- and adapter case for commercial vehicle  
set - VAS 6338/50- .  
♦ On refrigerant pipes without thread or union nut on the con‐  
nection, use adapter from adapter case for VW/Audi passen‐  
ger vehicle set - VAS 6338/1- or adapter case for commercial  
vehicle set - VAS 6338/50- or proprietary air gun with rubber  
nozzle.  
Note  
♦ Always extract any escaping air and/or nitrogen from the com‐  
ponents using appropriate local exhaust ventilation LEV (e.g.  
workshop extraction system).  
♦ Certain contaminants and old refrigerant oil cannot be shifted  
from the refrigerant circuit at all with compressed air or if the  
compressed air is insufficient. These contaminants can only  
be removed by purging with refrigerant R134a ⇒ page 67 .  
66  
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Air conditioning system with refrigerant R134a - Edition 10.2014  
7.1.1  
Blowing out refrigerant circuit  
Note  
♦ On vehicles where no adapters fit the refrigerant pipes, blow  
through individual components using an air gun, for example,  
with rubber nozzle. When doing this, be particularly careful not  
to damage the connections (do not crush or scratch them).  
♦ The evaporator should be blown through from the connection  
to the low-pressure side (large diameter), with the expansion  
valve or restrictor removed.  
♦ Always blow through components opposite the direction of re‐  
frigerant flow.  
♦ Examine the expansion valve; renew if dirty or corroded.  
lk  
♦ If components bear dark, sticky deposits which cannot be re‐  
moved with compressed air, renew these components.  
♦ Thin, light grey deposits on the insides of refrigerant pipes do  
not impair the function of the components.  
♦ After blowing out the system, always renew the receiver or  
reservoir and the restrictor. If the condenser has a dryer, re‐  
new the dryer cartridge or dryer.  
7.2  
Purging (cleaning) refrigerant circuit  
with refrigerant R134a  
Vehicles with high-voltage system (hybrid vehicles)  
Observe the additional warning instructions for working on vehi‐  
cles with high-voltage system ⇒ Electrical system; Rep. gr. 93 ;  
General warning instructions for work on the high-voltage sys‐  
tem .  
WARNING  
Risk of injury due to unexpected engine start  
When working on a high-voltage vehicle, switch off the ignition,  
and deposit the ignition key somewhere outside the passenger  
compartment.  
WARNING  
Handling high-voltage cables:  
•
Do not support yourself or your tools on high-voltage ca‐  
bles and their components --> risk of damage to the insu‐  
lation.  
•
•
High-voltage cables must not be extensively bent or  
kinked --> risk of damage to the insulation.  
The round high-voltage connectors are colour-coded with  
a coloured ring on the outside and mechanically coded  
with respective guide lugs. Always observe the coding  
when connecting the round high-voltage connectors in or‐  
der to prevent any mechanical damage to the high-voltage  
connectors.  
7. Clearing refrigerant circuit of contaminants  
67  
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DANGER!  
Hazardous voltage resulting from damaged high-voltage com‐  
ponents  
Observe the following when working in the vicinity of high-volt‐  
age components and cables:  
♦ Work involving metal-removing, deforming and sharp-  
edged tools or heat sources such as welding, soldering,  
hot air and thermal bonding is not permitted.  
♦ Before starting work, carry out a visual check on the high-  
voltage components in the area of work.  
♦ When working in the engine compartment, carry out a vis‐  
ual check on the power and control electronics for electric  
drive - JX1- , the electric drive motor - V141- , the air con‐  
ditioner compressor - V470- and the high-voltage cables.  
♦ When working on the underbody, carry out a visual check  
on the high-voltage cables and covers.  
♦ When working on the rear end, carry out a visual check on  
the high-voltage cables and the maintenance connector  
for high-voltage system - TW - .  
♦ Carry out a visual check on all potential equalisation lines.  
When carrying out the visual check, observe the following:  
♦ The high-voltage components must not reveal any exter‐  
nal damage.  
♦ The insulation of the high-voltage cables and the potential  
lk  
equalisation lines must not be damaged.  
♦ The high-voltage cables must not show any unusual de‐  
formations.  
♦ Each high-voltage component must be clearly identified  
with a red warning sticker.  
If repair work in the vicinity of high-voltage components and ca‐  
bles is necessary, “carry out a visual check for damage on high-  
voltage components and cables”, and “observe the general  
warning instructions for work on the high-voltage system” ⇒ Elec‐  
trical system; Rep. gr. 93 ; General warning instructions for work  
on the high-voltage system .  
If repair work on high-voltage components is necessary, de-en‐  
ergise the high-voltage system ⇒ Electrical system; Rep. gr. 93 ;  
De-energising high-voltage system , and “observe the general  
warning instructions for work on the high-voltage system” ⇒ Elec‐  
trical system; Rep. gr. 93 ; General warning instructions for work  
on the high-voltage system .  
68  
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Air conditioning system with refrigerant R134a - Edition 10.2014  
Caution  
♦ If there is evidence to suggest that chemical substances  
have been added in the vehicle to seal leaks, do not con‐  
nect the air conditioner service station and do not extract  
the refrigerant.  
♦ Chemical substances used to seal leaks form deposits in  
the refrigerant circuit. These can impair the function of the  
air conditioning system and cause the air conditioning  
system (and your air conditioner service station) to fail.  
♦ Make your customer aware of the fact that there are sub‐  
stances in his/her air conditioning system that do not have  
VW approval and therefore the refrigerant circuit cannot  
be purged. The refrigerant circuit can only be repaired by  
replacing all components that have come into contact with  
this substance.  
Note  
lk  
♦ Volkswagen rejects the use of chemical substances for pur‐  
poses of sealing leaks in refrigerant circuits.  
♦ Chemical substances used for sealing leaks in refrigerant cir‐  
cuits often react with the surrounding air and the humidity  
contained within. They cause deposits to build up in the re‐  
frigerant circuit (and your air conditioner service station),  
valves to malfunction and defects in other components with  
which they come into contact. These deposits cannot be com‐  
pletely removed from the components (not even by purging).  
The refrigerant circuit can only be repaired by replacing all  
components that have come into contact with this substance.  
♦ It is often not possible to detect from the outside whether  
chemical substances have been used to seal leaks in the re‐  
frigerant circuit. The adhesive label that serves to identify its  
use can usually not be found. Therefore, exercise caution on  
vehicles for which you have no service or repair record.  
•
To work as cleanly as possible and avoid the task becoming  
labour intensive when removing contaminants (e.g. friction  
dust and particles from defective air conditioner compressor)  
and old refrigerant oil, the refrigerant circuit must be purged  
using refrigerant R134a.  
On vehicles with electrical air conditioner compressor, observe  
the notes on renewing the electrical air conditioner compressor -  
V470-. If the electronics of the air conditioner compressor are  
damaged, the refrigerant circuit must not always be cleaned  
⇒ page 161 .  
The refrigerant circuit must be purged with refrigerant R134a if:  
♦ Dirt or other contaminants are in the refrigerant circuit.  
♦ If during evacuation of a leak-tight refrigerant circuit the vac‐  
uum display is not constant on gauge (moisture in the refrig‐  
erant circuit, which generates vapour pressure).  
♦ If the refrigerant circuit has been left open for longer than nor‐  
mally required for repairs (e.g. following an accident).  
♦ Pressure and temperature measurements in the refrigerant  
circuit indicate that there is moisture in the refrigerant circuit.  
♦ There is doubt about the amount of refrigerant oil in the refrig‐  
erant circuit. If the air conditioner compressor is to be reinstal‐  
led, drain refrigerant oil out of air conditioner compressor via  
7. Clearing refrigerant circuit of contaminants  
69  
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Air conditioning system with refrigerant R134a - Edition 10.2014  
the drain plug. 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. After purging, fill refrigerant cir‐  
cuit with total amount of refrigerant oil (50 g direct into air  
conditioner compressor) according to ⇒ vehicle-specific work‐  
lk  
shop manual . Observe additional oil requirements for systems  
with second evaporator.  
♦ The air conditioner compressor has to be exchanged because  
of internal damage (e.g. noisy or no output).  
♦ the vehicle-specific repair manual deems it necessary after  
replacement of certain components.  
♦ a different air conditioner compressor with other refrigerant oil  
is to be fitted.  
Tools required  
♦ Air conditioner service station with purging device - VAS 6381-  
or air conditioner service station with purging device - VAS  
6337- . These air conditioner service stations feature an ad‐  
ditional function for “purging the refrigerant circuit with R134a”  
and the purging device for refrigerant circuits necessary for  
this procedure ⇒ Workshop equipment and special tools cata‐  
logue .  
♦ Adapter case VW/Audi passenger vehicle set - VAS 6338/1-  
⇒ page 86 and ⇒ Workshop equipment and special tools  
catalogue .  
♦ Adapter case commercial vehicle set - VAS 6338/50-  
⇒ page 86 and ⇒ Workshop equipment and special tools  
catalogue .  
Note  
♦ If the above mentioned air conditioner service stations are not  
available in the workshop, purging device for refrigerant cir‐  
cuits - VAS 6336/1- or purging device for refrigerant circuits -  
VAS 6337/1- can be used to purge the refrigerant circuit,  
depending on the type of air conditioner service station in  
service (min. 7 kg refrigerant R134a in refrigerant bottle). The  
purging process must then be carried out manually  
⇒ page 75 .  
♦ On vehicles with threaded connections on the refrigerant cir‐  
cuit, adapter - V.A.G 1785/1- to adapter - V.A.G 1785/8- from  
adapter case VW/Audi passenger vehicle set - VAS 6338/1-  
or adapter case commercial vehicle set - VAS 6338/50- can  
be used. On vehicles with threaded connections on the air  
conditioner compressor and on the reservoir, the adapter -  
V.A.G 1785/8- is required two-fold.  
♦ In the adapter case there is also a charging hose - VAS  
6338/31- with 5/8 - 18 UNF connections and large internal di‐  
ameter to bridge components (commercially available type).  
Preliminary measures  
– Drain refrigerant circuit ⇒ page 49 .  
– Remove air conditioner compressor ⇒ Heating, air condition‐  
ing .  
On vehicles with restrictor and reservoir.  
– Remove restrictor (vehicle-specific) and join the refrigerant  
lines together again ⇒ Heating, air conditioning .  
– Remove reservoir (vehicle-specific) ⇒ Heating, air condition‐  
ing and join refrigerant pipes together again (to do this, use  
70  
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Air conditioning system with refrigerant R134a - Edition 10.2014  
adapter and charging hose - VAS 6338/31- from adapter case  
VW/Audi passenger vehicle set - VAS 6338/1- )  
⇒ page 86 .  
Note  
The collector could be purged but due to its large inner volume it  
would require too much refrigerant. During extraction, the refrig‐  
erant ices up the reservoir heavily and the extraction procedure  
takes much longer as a result.  
On vehicles with expansion valve and receiver.  
– Remove the receiver ⇒ Heating, air conditioning (vehicle-  
specific, not necessary on all vehicles) and join the refrigerant  
lines together (use the adapter and the charging hose - VAS  
6338/31- to do this) ⇒ page 86 .  
– Remove the expansion valve ⇒ Heating, air conditioning (ve‐  
hicle-specific) and insert an adapter in its place ⇒ page 86 .  
Note  
If there is not a suitable adapter for the expansion valve in the  
adapter case VW/Audi passenger vehicle set - VAS 6338/1- or  
adapter case commercial vehicle set - VAS 6338/50- , the re‐  
moved expansion valve can also be drilled out (the old expansion  
valve must be subsequently renewed).  
Caution  
♦ When drilling out, ensure that the sealing surfaces on the  
expansion valve are not damaged.  
♦ Refrigerant would otherwise escape.  
lk  
7. Clearing refrigerant circuit of contaminants  
71  
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Air conditioning system with refrigerant R134a - Edition 10.2014  
Note  
♦ Before drilling out, some parts have to be removed from the  
expansion valve.  
♦ There are two types of expansion valve. For type -A-, parts  
-B-, -C- and -D- must be removed. Separate regulator -E- from  
component -D-. Then drill through expansion valve in area  
-F- using a suitable 6 mm drill.  
♦ On version -G-, parts -H-, -I- and -K- must be removed and  
then area -L- drilled out with a suitably sized drill bit (6 mm in  
lk  
diameter).  
♦ Clean away any swarf from the drilled out expansion valve.  
♦ Reinstall parts -B-, -C- and -D- on type -A- or part -H- on type  
-G-.  
Note  
On vehicles with two evaporators, the circuit to the second evap‐  
orator must be isolated from the circuit to the first evaporator and  
purged in a separate procedure ⇒ Heating, air conditioning and  
⇒ page 86 .  
Drill open shut-off valve.  
72  
Rep. gr.00 - Technical data  
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Air conditioning system with refrigerant R134a - Edition 10.2014  
Note  
♦ Two shut-off valves are required for purging the refrigerant  
lk  
circuit. A shut-off valve must be drilled open, if no shut-off tap  
- VAS 6338/42- is available, for example.  
♦ Remove the solenoid -A- and the solenoid valve -B- before  
drilling open the shut-off valve.  
♦ Drill open the shut-off valve -C- using a suitable drill bit (e.g.  
5 mm in diameter).  
♦ Remove any metal shavings resulting from drilling hole -D-  
from shut-off valve -C-.  
♦ Reinstall the solenoid valve -B- with the respective seal -E- to  
the shut-off valve -C- which has been drilled open.  
Purging  
– Check the refrigerant volume in the air conditioning bottle.  
There must be at least 7 kg of R134a refrigerant.  
Note  
Switch on the heater attached to the refrigerant bottle 30 minutes  
before the first purging process, if necessary. In this way, pres‐  
sure in the refrigerant bottle is increased and charging of the  
purging circuit is accelerated.  
– Drain the waste oil container of the air conditioner service sta‐  
tion.  
– Connect the supply hose (high-pressure side) of the air con‐  
ditioner service station with an adapter ⇒ page 86 to the low-  
pressure line leading to the air conditioner compressor (line  
with larger diameter).  
– Connect the return hose (low-pressure or suction side) of the  
air conditioner service station to the outlet of the purging de‐  
vice for refrigerant circuits.  
– Connect the inlet of the purging device for refrigerant circuits  
with an adapter ⇒ page 86 to the high-pressure line leading  
to the air conditioner compressor (line with smaller diameter).  
7. Clearing refrigerant circuit of contaminants  
73  
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Air conditioning system with refrigerant R134a - Edition 10.2014  
lk  
Note  
♦ The components must always be purged against the direction  
of refrigerant flow when the air conditioning system is in oper‐  
ation (not applicable for electrical air conditioner compressor)  
⇒ page 77 .  
♦ When purging, contaminants from the refrigerant circuit enter  
the purging device for refrigerant circuits and the air condi‐  
tioner service station and are retained in the filters and dryers  
installed within. Depending on the contaminants, these com‐  
ponents must be changed at shorter intervals in accordance  
with the operating instructions for the air conditioner service  
station or purging device for refrigerant circuits.  
♦ The filter in the purging device for refrigerant circuits should  
be changed after about 2 purging cycles (purged vehicles),  
depending on the level of contamination from the purged re‐  
frigerant circuits. If a heavily contaminated refrigerant circuit is  
purged (the refrigerant oil from the refrigerant circuit is black  
and viscous or there are large amounts of shavings in the re‐  
frigerant circuit) renew filter after purging refrigerant circuit.  
After such heavy contamination of the refrigerant circuit, we  
suggest purging the system again after changing the filter.  
♦ Depending on the type of contamination, deposits (old refrig‐  
erant oil and abrasive wear particles from the air conditioner  
compressor) will gather in the sight glass(es) of the purging  
device for refrigerant circuits. Clean sight glass(es) after purg‐  
ing and purge refrigerant circuits again.  
♦ Fluid refrigerant cannot flow at the necessary speed through  
the expansion valve, the restrictor and the dryer cartridge of  
certain receivers. These components must therefore be re‐  
moved and an adapter installed in their place ⇒ Heating, air  
conditioning .  
♦ Adapters to connect air conditioner service station and to  
bridge certain components of refrigerant circuit ⇒ page 86 .  
– Switch on the air conditioner service station and purge the re‐  
frigerant circuit (duration approx. 1 to 1.5 hours for one purging  
cycle with three purgings using approx 4 Kg refrigerant  
R134a).  
74  
Rep. gr.00 - Technical data  
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Air conditioning system with refrigerant R134a - Edition 10.2014  
Note  
lk  
♦ The purging process of the refrigerant circuit should be carried  
out in accordance with the operating instructions of the air  
conditioner service station  
♦ Depending on the type of air conditioner service station, the  
3
waste oil container has a capacity of only approx. 125 cm . If  
a system with a greater amount of refrigerant oil has to be  
purged, it may be necessary to empty the waste oil container  
after the first purge of the purging cycle.  
♦ Watch the refrigerant that flows out of the refrigerant circuit.  
When the refrigerant flows through the sight glass of the purg‐  
ing device into the air conditioner service station clear and  
completely free of colour, the refrigerant circuit is cleaned.  
♦ When purging, the whole amount of refrigerant oil from the  
refrigerant circuit is cleaned (except for a small amount in the  
evaporator, though this is not important).  
♦ Where contamination is particularly high, it may be necessary  
to carry out the purging cycle twice (two purging cycles with  
three purges each). Purging device filter must be renewed be‐  
fore starting second purging cycle.  
Sequence of purging process (sequence is carried out automati‐  
cally in accordance with the air conditioner service station pro‐  
gramme)  
♦ After switching on, the purging cycle (refrigerant circuit with  
connection hoses and purging device for refrigerant circuits)  
is first evacuated and the refrigerant circuit thereby checked  
for leaks. Depending on the type of air conditioner service sta‐  
tion, it may be necessary to continue the sequence manually.  
♦ In the evacuated purging circuit, a predetermined amount of  
refrigerant is filled (e.g. 4 kg) via the high-pressure side of the  
air conditioner service station (against the normal direction of  
flow for air conditioner operation and thereby on the low-pres‐  
sure side of the vehicle refrigerant circuit). Depending on the  
type of air conditioner service station, refrigerant is filled until  
the purging circuit is completely filled with liquid refrigerant.  
This can be identified, for example, by the fact that after a cer‐  
tain period of time no more refrigerant flows through.  
♦ Once the predetermined amount of refrigerant has been filled  
in the system, the heater, for example, of the purging device  
for refrigerant circuits is switched on depending on the type of  
air conditioner service station and purging device for refriger‐  
ant circuits (only if the refrigerant is extracted in gaseous form  
out of the purging device for refrigerant circuits).  
♦ When the refrigerant has been extracted, the heater of the  
purging device (if fitted) for refrigerant circuits is switched off,  
the refrigerant circuit may have to be evacuated briefly again  
depending on the design, and following evacuation so that the  
air conditioner service station can separate out the refrigerant  
oil.  
♦ The sequence for filling with refrigerant, extracting (and evac‐  
uating) is carried out twice (that means a total of three times).  
♦ After extracting for the third time, the purging circuit is evacu‐  
ated depending on the type of air conditioner service station.  
7. Clearing refrigerant circuit of contaminants  
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Air conditioning system with refrigerant R134a - Edition 10.2014  
– Once the purging cycle is complete, check the sight glass (or  
sight glasses) for refrigerant circuits. If this is dirty, clean it in  
accordance with the operating instructions of the purging de‐  
vice for refrigerant circuits or the air conditioner service station.  
Carry out a purging cycle once more as a precautionary meas‐  
ure. One purging cycle is sufficient (approx. 30 min.).  
– Check the pressure in the refrigerant circuit. There must be no  
pressure in the refrigerant circuit (evacuate again briefly if  
necessary).  
– Remove the connections to the air conditioning service station  
from the refrigerant circuit of the vehicle (there should be no  
pressure in the refrigerant circuit)  
– Renew these components according to the type of vehicle.  
♦ Restrictor and reservoir  
♦ Expansion valve and receiver or dryer cartridge in receiver  
lk  
– ⇒ Heating, air conditioning and ⇒ Parts catalogue .  
– Replace air conditioner compressor depending on complaint  
⇒ Heating, air conditioning and ⇒ Parts catalogue or drain  
the remaining refrigerant oil from the removed air conditioner  
compressor ⇒ page 159 (renewing components of refrigerant  
circuit) and fill it with the prescribed amount of fresh refrigerant  
oil ⇒ vehicle-specific workshop manual .  
Note  
♦ There is a predetermined amount of refrigerant oil in the gen‐  
uine air conditioner compressor. On vehicles with two evapo‐  
rators, a certain amount of refrigerant oil may have to be added  
to the circuit as appropriate ⇒ vehicle-specific workshop man‐  
ual .  
♦ If the air conditioner compressor does not have to be renewed,  
the volume of refrigerant oil in the air conditioner compressor  
must be replenished in accordance with the fill volume (pour  
out refrigerant oil and refill the prescribed amount in the air  
conditioner compressor or the refrigerant circuit)  
⇒ page 159 (renewing components of refrigerant circuit) and  
⇒ vehicle-specific workshop manual .  
– Assemble the refrigerant circuit back together again complete‐  
ly ⇒ Heating, air conditioning .  
– Evacuate and fill the refrigerant circuit as per specifications  
⇒ page 51 and ⇒ page 50 .  
– Bring the air conditioning system into operation as per speci‐  
fications ⇒ Heating, air conditioning and ⇒ page 52 .  
76  
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Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...  
Air conditioning system with refrigerant R134a - Edition 10.2014  
7.2.1  
Principle circuit diagrams for various  
purging circuits  
Note  
♦ The arrows in the following illustrations show the direction of  
flow of the refrigerant during purging. The refrigerant flows  
against the direction of flow during normal conditioning of the  
air, which is why the high-pressure system of the air condi‐  
tioner service station is connected to the low-pressure con‐  
nection of the refrigerant circuit to the air conditioner  
compressor.  
♦ These principle circuit diagrams show a refrigerant circuit with  
restrictor and reservoir and a refrigerant circuit with expansion  
valve, receiver and a second evaporator (extra equipment on  
certain vehicles).  
♦ Depending on the design of the air conditioner service station,  
non-return valves may be installed between the refrigerant  
circuit and the air conditioner service station. This ensures the  
correct direction of flow of refrigerant during purging.  
Refrigerant circuit with restrictor and reservoir  
lk  
Note  
On vehicles with restrictor and reservoir, the restrictor and the  
reservoir are removed. The refrigerant pipes of the restrictor are  
assembled again. The refrigerant pipes to the removed reservoir  
are joined together with two adapters and the charging hose -  
VAS 6338/31- (from adapter case VW/Audi passenger vehicle set  
- VAS 6338/1- .  
7. Clearing refrigerant circuit of contaminants  
77  
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Air conditioning system with refrigerant R134a - Edition 10.2014  
1 - Air conditioner service sta‐  
tion  
❑ With electronics and a  
purging programme e.g.  
air conditioner service  
station - VAS 6380- with  
purging device or air  
conditioner service sta‐  
tion with purging device  
- VAS 6337- .  
❑ If an air conditioner  
service station without  
purging programme is  
used, the sequence has  
to be carried out man‐  
ually (evacuate, purge  
3 times with at least 4 kg  
of refrigerant each time  
and extract refrigerant  
again, evacuate).  
2 - Refrigerant hose of air con‐  
ditioner service station  
❑ From high pressure side  
of air conditioner service  
station (normally col‐  
oured red) to connection  
for low pressure side of  
air conditioner compres‐  
sor on refrigerant circuit  
(larger diameter)  
3 - Adapter to connection for  
low-pressure side on refriger‐  
ant circuit  
❑ Different versions de‐  
pending on vehicle  
⇒ page 86 .  
❑ From adapter case VW/  
Audi passenger vehicle  
set - VAS 6338/1- .  
4 - Connection for low-pressure side on refrigerant circuit  
❑ Different versions depending on vehicle ⇒ page 86 .  
❑ On refrigerant line from air conditioner compressor to reservoir  
5 - Connection to reservoir  
❑ Different versions depending on vehicle ⇒ page 86 .  
❑ On refrigerant line from air conditioner compressor to reservoir  
6 - Adapter to bridge removed reservoir  
❑ Different versions depending on vehicle ⇒ page 86 .  
❑ From adapter case VW/Audi passenger vehicle set - VAS 6338/1- .  
7 - Charging hose for refrigerant ⇒ page 86  
❑ For example charging hose - VAS 6338/31- (from adapter case VW/Audi passenger vehicle set - VAS  
6338/1- ).  
8 - Adapter to bridge removed reservoir  
❑ Different versions depending on vehicle ⇒ page 86 .  
❑ From adapter case VW/Audi passenger vehicle set - VAS 6338/1- .  
9 - Connection to reservoir  
❑ Different versions depending on vehicle ⇒ page 86 .  
78  
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Air conditioning system with refrigerant R134a - Edition 10.2014  
10 - Evaporator  
11 - Location of restrictor  
❑ The restrictor is removed.  
❑ Removing restrictor ⇒ Heating, air conditioning .  
12 - Threaded connection in refrigerant line  
lk  
❑ After removing the restrictor, screw back together again ⇒ Heating, air conditioning .  
13 - Condenser  
14 - Connection for high-pressure side on refrigerant circuit  
❑ Different versions depending on vehicle ⇒ page 86 .  
15 - Adapter to connection for high-pressure side on refrigerant circuit  
❑ Different versions depending on vehicle ⇒ page 86 .  
❑ From adapter case VW/Audi passenger vehicle set - VAS 6338/1- .  
16 - Charging hose of flushing device for refrigerant circuits  
❑ From connection to high-pressure side of air conditioner compressor on refrigerant circuit (smaller di‐  
ameter) to inlet of purging device for refrigerant circuits - VAS 6336/1- or purging device for refrigerant  
circuits - VAS 6337/1- .  
17 - Purging device for refrigerant circuits  
❑ Different versions and different design e.g. purging device for refrigerant circuits - VAS 6336/1- or purging  
device for refrigerant circuits - VAS 6337/1- .  
❑ With filter, sight glass, safety valve, heating, refrigerant tank, etc. (depending on version).  
❑ Depending on the design of the air conditioner service station and the purging device for refrigerant  
circuits, there may be a non-return valve installed at the outlet of the purging device for refrigerant circuits  
(to assure the correct direction of refrigerant flow during purging).  
18 - Refrigerant hose of air conditioner service station  
❑ From the low-pressure side of the air conditioner service station (normally coloured blue) to the outlet of  
the purging device for refrigerant circuits  
Refrigerant circuit with expansion valve, receiver and second  
evaporator  
Note  
♦ This principle circuit diagram shows a refrigerant circuit with  
expansion valve, receiver and a second evaporator (extra  
equipment on certain vehicles).  
♦ On vehicles with expansion valve and receiver, the expansion  
valve is removed and an adapter installed in its place. The  
receiver must be purged, depending on the vehicle or the dryer  
cartridge removed. Depending on the type of receiver, this  
should be removed and the line connections to the receiver  
joined together using two adapters and a charging hose.  
♦ On vehicles with just one evaporator, the components from  
position “16” are not installed or not required.  
7. Clearing refrigerant circuit of contaminants  
79  
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1 - Air conditioner service sta‐  
tion  
❑ With electronics and a  
purging programme e.g.  
air conditioner service  
station - VAS 6380- with  
purging device or air  
conditioner service sta‐  
tion with purging device  
- VAS 6337- .  
❑ If an air conditioner  
service station is used  
which does not have a  
purging programme,  
then the sequence must  
be performed manually.  
–
–
Extract refrigerant, if  
there is any in the sys‐  
tem.  
Connect purging device  
for refrigerant circuits -  
VAS 6336/1- or purging  
device for refrigerant cir‐  
cuits - VAS 6337/1- be‐  
tween air conditioner  
service station and re‐  
turn line for refrigerant  
circuit.  
–
Evacuate refrigerant cir‐  
cuit for 20 minutes, then  
fill system with 4 kg of  
refrigerant R134a. Then  
extract again and repeat  
process two further  
times. If after the 3rd  
purging process the re‐  
frigerant in the sight  
glass/glasses is not clear, repeat process again.  
2 - Refrigerant hose of air conditioner service station  
❑ From high pressure side of air conditioner service station (normally coloured red) to connection for low  
pressure side of air conditioner compressor on refrigerant circuit (larger diameter)  
3 - Adapter to connection for low-pressure side on refrigerant circuit  
❑ Different versions depending on vehicle ⇒ page 86 .  
❑ From adapter case VW/Audi passenger vehicle set - VAS 6338/1- .  
4 - Connection for low-pressure side on refrigerant circuit  
❑ Different versions depending on vehicle ⇒ page 86 .  
5 - Adapter for removed expansion valve  
❑ Different versions depending on vehicle ⇒ page 86 .  
❑ From adapter case VW/Audi passenger vehicle set - VAS 6338/1- .  
6 - Evaporator  
7 - Connection to receiver  
❑ Different versions depending on vehicle ⇒ page 86 .  
❑ Not included on vehicles with a dryer cartridge in the receiver on the condenser or one in the receiver  
integrated within the condenser ⇒ Heating, air conditioning .  
8 - Adapter to bridge removed receiver  
❑ Not required on all vehicles.  
80  
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Air conditioning system with refrigerant R134a - Edition 10.2014  
❑ Different versions depending on vehicle ⇒ page 86 .  
❑ From adapter case VW/Audi passenger vehicle set - VAS 6338/1- .  
9 - Charging hose for refrigerant ⇒ page 86  
❑ For example charging hose - VAS 6338/31- (from adapter case VW/Audi passenger vehicle set - VAS  
6338/1- ).  
10 - Condenser  
❑ If there is a receiver with dryer cartridge installed on the condenser, the dryer cartridge must be removed  
(seal receiver again on or in condenser following removal) ⇒ Heating, air conditioning .  
❑ If the receiver is attached directly to the condenser, remove the receiver after purging and renew ⇒  
Heating, air conditioning .  
11 - Connection for high-pressure side on refrigerant circuit  
❑ Different versions depending on vehicle ⇒ page 86 .  
12 - Adapter to connection for high-pressure side on refrigerant circuit  
❑ Different versions depending on vehicle ⇒ page 86 .  
❑ From adapter case VW/Audi passenger vehicle set - VAS 6338/1- .  
13 - Charging hose of flushing device for refrigerant circuits  
❑ From connection to high pressure side of air conditioner compressor on refrigerant circuit (smaller di‐  
ameter) to inlet of purging device for refrigerant circuits.  
14 - Purging device for refrigerant circuits  
lk  
❑ Different versions and different design e.g. purging device for refrigerant circuits - VAS 6336/1- or purging  
device for refrigerant circuits - VAS 6337/1- .  
❑ With filter, sight glass, safety valve, heating, refrigerant tank, etc. (depending on version).  
❑ Depending on the design of the air conditioner service station and the purging device for refrigerant  
circuits, there may be a non-return valve installed at the outlet of the purging device for refrigerant circuits  
(to assure the correct direction of refrigerant flow during purging).  
15 - Refrigerant hose of air conditioner service station  
❑ From the low-pressure side of the air conditioner service station (normally coloured blue) to the outlet of  
the purging device for refrigerant circuits  
16 - Adapter to seal outlet to second evaporator  
❑ Only required on certain vehicles with “second evaporator” (optional equipment).  
❑ From adapter case commercial vehicle set - VAS 6338/50- .  
17 - Adapter to seal outlet to second evaporator  
❑ Only required on certain vehicles with “second evaporator” (optional equipment).  
❑ From adapter case commercial vehicle set - VAS 6338/50- .  
18 - Connection of low-pressure side on refrigerant circuit to second evaporator  
❑ Different versions depending on vehicle ⇒ page 86 .  
❑ Only fitted on certain vehicles with “second evaporator” (optional equipment).  
19 - Connection of high-pressure side on refrigerant circuit to second evaporator  
❑ Different versions depending on vehicle ⇒ page 86 .  
❑ Only fitted on certain vehicles with “second evaporator” (optional equipment).  
20 - Adapter for removed expansion valve on second evaporator  
❑ Different versions depending on vehicle ⇒ page 86 .  
❑ Only required on certain vehicles with “second evaporator” (optional equipment).  
❑ From adapter case commercial vehicle set - VAS 6338/50- .  
21 - Second evaporator  
❑ Only fitted on certain vehicles with “second evaporator” (optional equipment).  
7. Clearing refrigerant circuit of contaminants  
81  
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7.2.2  
Purging electrical air conditioner com‐  
pressor  
Vehicles with high-voltage system  
lk  
Observe the additional warning instructions for working on vehi‐  
cles with high-voltage system ⇒ Electrical system; Rep. gr. 93 ;  
General warning instructions for work on the high-voltage sys‐  
tem .  
WARNING  
Risk of injury due to unexpected engine start  
When working on a high-voltage vehicle, switch off the ignition,  
and deposit the ignition key somewhere outside the passenger  
compartment.  
WARNING  
Handling high-voltage cables:  
•
Do not support yourself or your tools on high-voltage ca‐  
bles and their components --> risk of damage to the insu‐  
lation.  
•
•
High-voltage cables must not be extensively bent or  
kinked --> risk of damage to the insulation.  
The round high-voltage connectors are colour-coded with  
a coloured ring on the outside and mechanically coded  
with respective guide lugs. Always observe the coding  
when connecting the round high-voltage connectors in or‐  
der to prevent any mechanical damage to the high-voltage  
connectors.  
82  
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Air conditioning system with refrigerant R134a - Edition 10.2014  
DANGER!  
Hazardous voltage resulting from damaged high-voltage com‐  
ponents  
Observe the following when working in the vicinity of high-volt‐  
age components and cables:  
♦ Work involving metal-removing, deforming and sharp-  
edged tools or heat sources such as welding, soldering,  
hot air and thermal bonding is not permitted.  
♦ Before starting work, carry out a visual check on the high-  
voltage components in the area of work.  
♦ When working in the engine compartment, carry out a vis‐  
ual check on the power and control electronics for electric  
drive - JX1- , the electric drive motor - V141- , the air con‐  
ditioner compressor - V470- and the high-voltage cables.  
lk  
♦ When working on the underbody, carry out a visual check  
on the high-voltage cables and covers.  
♦ When working on the rear end, carry out a visual check on  
the high-voltage cables and the maintenance connector  
for high-voltage system - TW - .  
♦ Carry out a visual check on all potential equalisation lines.  
When carrying out the visual check, observe the following:  
♦ The high-voltage components must not reveal any exter‐  
nal damage.  
♦ The insulation of the high-voltage cables and the potential  
equalisation lines must not be damaged.  
♦ The high-voltage cables must not show any unusual de‐  
formations.  
♦ Each high-voltage component must be clearly identified  
with a red warning sticker.  
If repair work in the vicinity of high-voltage components and ca‐  
bles is necessary, “carry out a visual check for damage on high-  
voltage components and cables”, and “observe the general  
warning instructions for work on the high-voltage system” ⇒ Elec‐  
trical system; Rep. gr. 93 ; General warning instructions for work  
on the high-voltage system .  
If repair work on high-voltage components is necessary, de-en‐  
ergise the high-voltage system ⇒ Electrical system; Rep. gr. 93 ;  
De-energising high-voltage system , and “observe the general  
warning instructions for work on the high-voltage system” ⇒ Elec‐  
trical system; Rep. gr. 93 ; General warning instructions for work  
on the high-voltage system .  
Note  
The electrical air conditioner compressor must be purged, if you  
suspect that there is too much refrigerant oil in the refrigerant cir‐  
cuit or if contaminated refrigerant oil (contaminated with moisture)  
must be extracted from the air conditioner compressor. In these  
cases the refrigerant circuit must be purged as well in order to  
clean the refrigerant circuit and to re-establish the correct amount  
of refrigerant oil.  
If an electrical air conditioner compressor is renewed without hav‐  
ing a mechanical fault (e.g. defective printed circuit board), the  
7. Clearing refrigerant circuit of contaminants  
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Air conditioning system with refrigerant R134a - Edition 10.2014  
amount of refrigerant oil from this electrical air conditioner com‐  
pressor must be determined.  
Note  
♦ The air conditioner compressor must be purged in order to  
extract the refrigerant oil which needs to be determined.  
♦ Purge the air conditioner compressor in normal direction of  
flow (from low-pressure inlet to high-pressure outlet).  
♦ In order to purge as much refrigerant oil from the air condi‐  
tioner compressor as possible make sure that the high-pres‐  
sure outlet of the air conditioner compressor is in the lowest  
position possible.  
♦ If an air conditioner service station without purging programme  
is used, the sequence has to be carried out manually (evacu‐  
ate, purge 3 times with at least 2 kg of refrigerant each time  
and extract refrigerant again, evacuate).  
Determined amount e.g. 50 cm³  
Then, remove as much refrigerant oil from the new air conditioner  
compressor as is necessary to ensure that only the same amount  
of refrigerant oil which has been purged from the old air condi‐  
3
tioner compressor remains in the new one (plus 10 cm ). If, for  
example, the new original air conditioner compressor is filled with  
3
3
e.g. 200 cm of refrigerant oil, then remove only 140 cm .  
– Pour old refrigerant oil out of air conditioner compressor. Han‐  
dling refrigerant ⇒ Volkswagen ServiceNet; Service hand‐  
book; Environmental protection; Waste disposal; Current  
situation; Disposal channels; Disposal of used oils; Refrigerant  
lk  
oils .  
Note  
If the amount of refrigerant oil which can be removed from the  
new air conditioner compressor is not sufficient, the new air con‐  
ditioner compressor must be purged. After the new air conditioner  
compressor has been purged, fill the amount of refrigerant oil  
which has been determined when purging the old air conditioner  
compressor.  
84  
Rep. gr.00 - Technical data  
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...  
Air conditioning system with refrigerant R134a - Edition 10.2014  
1 - Air conditioner service sta‐  
tion  
Note  
The air conditioner com
purged manually.  
–
–
Extract refrigerant, if  
there is any in the sys‐  
tem.  
Empty the used-oil con‐  
tainer of the air condi‐  
tioner service station.  
Note  
Some air conditioner se
tions first separate the o
uum phase and then fill
used-oil container.  
–
–
At the air conditioner  
service station, set the  
amount of refrigerant to  
2 kg and the amount of  
oil to 0.  
Connect purging device  
for refrigerant circuits -  
VAS 6336/1- or purging  
device for refrigerant cir‐  
cuits - VAS 6337/1- be‐  
tween air conditioner  
service station and re‐  
turn line for refrigerant  
circuit.  
–
Evacuate the refrigerant  
circuit for 10 minutes. Then observe the vacuum gauge. If the vacuum persists, fill 2 kg of R134a refrig‐  
erant into the circuit. Then, extract and evacuate again and repeat the process.  
2 - Refrigerant hose of air conditioner service station  
❑ From the low-pressure side of the air conditioner service station (normally coloured blue) to the outlet of  
the purging device for refrigerant circuits  
3 - Purging device for refrigerant circuits  
❑ Different versions and different design e.g. purging device for refrigerant circuits - VAS 6336/1- or purging  
device for refrigerant circuits - VAS 6337/1- .  
❑ With filter, sight glass, safety valve, heating, refrigerant tank, etc. (depending on version).  
❑ Depending on the design of the air conditioner service station and the purging device for refrigerant  
circuits, there may be a non-return valve installed at the outlet of the purging device for refrigerant circuits  
(to assure the correct direction of refrigerant flow during purging).  
4 - Charging hose of flushing device for refrigerant circuits  
❑ From connection to high-pressure side of air conditioner compressor on refrigerant circuit (smaller di‐  
ameter) to inlet of purging device for refrigerant circuits - VAS 6336/1- or purging device for refrigerant  
circuits - VAS 6337/1- .  
5 - Adapter to connection for high-pressure side on refrigerant circuit  
❑ Adapter - VAS 6338/3- from adapter set for refrigerant circuits - VAS 6338/1-  
7. Clearing refrigerant circuit of contaminants  
85  
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Note  
If the adapter - VAS 6338/40- is  
available, the charging hose can be  
connected directly to the air condi‐  
tioner compressor.  
6 - High-pressure side refrigerant line from air conditioner compressor  
Note  
Will not be used if the adapter - VAS  
6338/40- is available.  
–
Pull the centring pin out of the refrigerant line so that the adapter - VAS 6338/3- fits properly.  
7 - Electrical air conditioner compressor  
❑ Purge the air conditioner compressor in normal direction of flow (from low-pressure inlet to high-pressure  
outlet).  
❑ In order to purge as much refrigerant oil from the air conditioner compressor as possible make sure that  
the high-pressure outlet of the air conditioner compressor is in the lowest position possible.  
8 - Low-pressure side refrigerant line to air conditioner compressor  
Note  
Will not be used if the adapter - VAS  
6338/41- is available.  
–
Pull the centring pin out of the refrigerant line so that the adapter - VAS 6338/6- fits properly.  
9 - Adapter to connection for low-pressure side on refrigerant circuit  
❑ Adapter - VAS 6338/6- from adapter set for refrigerant circuits - VAS 6338/1-  
Note  
If the adapter - VAS 6338/41- is  
available, the charging hose can be  
connected directly to the air condi‐  
tioner compressor.  
10 - Refrigerant hose of air conditioner service station  
❑ From high-pressure side of the air conditioner service station (usually coloured in red) for connection to  
low-pressure line or directly to air conditioner compressor using adapter - VAS 6338/41- .  
7.2.3  
Adapters for setting up purging circuits  
♦ The following table contains the various adapters that are nec‐  
essary to connect the air conditioner service station to the  
refrigerant circuit for purposes of purging and to bridge the re‐  
moved reservoir or collector and expansion valve (vehicle-  
specific).  
♦ Using a filling hose with 5/8 -18 UNF connections (short ver‐  
sion, e.g. charging hose - VAS 6338/31- ), join both adapters,  
which were installed in place of the reservoir or receiver (in‐  
cluded in adapter case VW/Audi passenger vehicle set - VAS  
6338/1- ).  
♦ If a purged refrigerant circuit is not going to be reassembled  
straight after purging, leave the adapters on the connections  
and seal the connections at the adapters using the sealing  
caps - VAS 6338/30- (from adapter case VW/Audi passenger  
vehicle set - VAS 6338/1- ).  
86  
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Air conditioning system with refrigerant R134a - Edition 10.2014  
♦ Depending on the type of air conditioner compressor and the  
period of production, different joining and sealing techniques  
have been applied in the refrigerant circuit ⇒ Heating, air con‐  
ditioning .  
Block or threaded connections  
Threaded connection -A-  
Block connection -B-  
lk  
7. Clearing refrigerant circuit of contaminants  
87  
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lk  
Block connections with various types of seals  
Block connection with radial sealing connection -A- (with guide  
made from plastic or metal -B-)  
– Block connection with axial sealing connection -C-  
Fox 2005  
Vehicle Adapters re‐  
Adapters required for Miscella‐  
quired for refrig‐ refrigerant pipes to re‐ neous  
erant pipes to air ceiver  
conditioner com‐  
pressor  
Fox  
♦ Low-pres‐  
sure side  
adapter -  
VAS  
– Remove dryer car‐ – Install  
2005 ►  
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 6338/2-  
drilled  
out ex‐  
pan‐  
sion  
valve  
⇒
pa  
ge 71 )  
– After  
purg‐  
ing, in‐  
stall a  
new ex‐  
pan‐  
sion  
valve.  
88  
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Air conditioning system with refrigerant R134a - Edition 10.2014  
Lupo 1999  
Vehicle Adapters re‐  
Adapters required for Miscella‐  
quired for refrig‐ refrigerant pipes to re‐ neous  
erant pipes to air ceiver  
conditioner com‐  
pressor  
Lupo  
♦ Low-pres‐  
sure side  
adapter -  
VAS  
– Remove receiver  
and bridge refriger‐  
ant pipes.  
– Install  
adapter  
- VAS  
6338/1  
9- in  
1999 ►  
up to ve‐  
hicle  
♦ Adapter - VAS  
6338/28-  
identifi‐  
cation  
number  
70000  
6338/12-  
place of  
expan‐  
sion  
♦ High-pres‐  
sure side  
♦ Adapter - VAS  
6338/29-  
adapter -  
valve  
– After flushing, in‐  
stall a new receiver.  
VAS 6338/2-  
(or dril‐  
led out  
expan‐  
sion  
valve  
e.g. 6N  
0 820  
679 C  
⇒
pa  
ge 71 )  
– After  
purg‐  
lk  
ing, in‐  
stall a  
new ex‐  
pan‐  
sion  
valve.  
Lupo  
♦ Low-pres‐  
sure side  
adapter -  
VAS  
Receiver  
– Install  
adapter  
- VAS  
6338/1  
9- in  
1999 ►  
from ve‐  
hicle  
– Can be flushed  
through.  
identifi‐  
cation  
number  
70001  
6338/12-  
– After flushing, in‐  
stall a new receiver.  
place of  
expan‐  
sion  
♦ High-pres‐  
sure side  
adapter -  
VAS 6338/2-  
or  
valve  
(or dril‐  
led out  
expan‐  
sion  
♦ Adapter -  
VAS 6338/7-  
valve  
e.g. 6N  
0 820  
679 C  
⇒
pa  
ge 71 )  
– After  
purg‐  
ing, in‐  
stall a  
new ex‐  
pan‐  
sion  
valve.  
7. Clearing refrigerant circuit of contaminants  
89  
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...  
Air conditioning system with refrigerant R134a - Edition 10.2014  
up! 2012; e-up! 2014  
Vehicle Adapters re‐  
Adapters required for Miscella‐  
quired for refrig‐ refrigerant pipes to re‐ neous  
erant pipes to air ceiver  
conditioner com‐  
lk  
pressor  
up!  
♦ Low-pres‐  
sure side  
adapter -  
VAS  
Receiver  
– Re‐  
2012 ►;  
e-up!  
– Can be flushed  
through.  
place  
expan‐  
sion  
2014 ►  
6338/12-  
– After flushing, in‐  
stall a new receiver.  
valve  
with  
♦ High-pres‐  
sure side  
adapter  
- VAS  
6338/3  
6- or  
adapter -  
VAS 6338/3-  
adapter  
- VAS  
6338/3  
4- (or  
drilled-  
out ex‐  
pan‐  
♦ Purging elec‐  
trical air con‐  
ditioner com‐  
pressor,  
adapter -  
VAS  
6338/40- and  
Adapter -  
VAS  
sion  
valve  
e.g. 1S  
0 820  
078  
6338/41- ,  
Observe  
notes:  
⇒
⇒ page 82  
pa  
ge 71 ).  
– After  
purg‐  
ing, in‐  
stall a  
new ex‐  
pan‐  
sion  
valve.  
90  
Rep. gr.00 - Technical data  
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...  
Air conditioning system with refrigerant R134a - Edition 10.2014  
Polo 1995  
Vehicle Adapters re‐  
Adapters required for Miscella‐  
quired for refrig‐ refrigerant pipes to re‐ neous  
erant pipes to air ceiver  
conditioner com‐  
pressor  
Polo  
Adapter - VAS  
– Remove receiver  
and bridge refriger‐  
ant pipes.  
– Install  
adapt‐  
er -  
1995 ► 6338/14-  
up to ve‐  
hicle  
♦ Adapter - VAS  
6338/28-  
VAS  
identifi‐  
6338/1  
9- in  
cation  
♦ Adapter - VAS  
6338/29-  
number  
50000  
place  
of ex‐  
pan‐  
– After flushing, in‐  
stall a new receiver.  
sion  
valve  
lk  
(or dril‐  
led out  
expan‐  
sion  
valve  
e.g. 6N  
0 820  
679 C  
⇒ page  
71 )  
– After  
purg‐  
ing, in‐  
stall a  
new  
expan‐  
sion  
valve.  
Polo  
♦ Low-pres‐  
Receiver  
– Install  
adapt‐  
er -  
1995 ►  
from ve‐  
hicle  
sure side  
– Can be flushed  
through.  
adapter -  
VAS 6338/7-  
VAS  
identifi‐  
cation  
number  
50001  
– After flushing, in‐  
stall a new receiver.  
6338/1  
9- in  
♦ High-pres‐  
sure side  
place  
of ex‐  
pan‐  
adapter -  
VAS 6338/2-  
sion  
valve  
(or dril‐  
led out  
expan‐  
sion  
valve  
e.g. 6N  
0 820  
679 C  
⇒ page  
71 )  
– After  
purg‐  
ing, in‐  
stall a  
new  
expan‐  
sion  
valve.  
7. Clearing refrigerant circuit of contaminants  
91  
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...  
Air conditioning system with refrigerant R134a - Edition 10.2014  
Polo 2002  
Vehicle Adapters re‐  
Adapters required for Miscella‐  
quired for refrig‐ refrigerant pipes to re‐ neous  
erant pipes to air ceiver  
conditioner com‐  
pressor  
Polo  
♦ Low-pres‐  
sure side  
adapter -  
VAS  
– Remove dryer car‐ – Install  
2002 ►  
tridge and seal re‐  
ceiver.  
adapt‐  
er -  
VAS  
lk  
6338/12-  
– After flushing, in‐  
stall a new dryer  
cartridge.  
6338/3  
4- in  
♦ High-pres‐  
sure side  
place  
of ex‐  
pan‐  
adapter -  
VAS 6338/2-  
sion  
valve  
(or a  
drilled  
out ex‐  
pan‐  
sion  
valve  
⇒ page  
71 )  
– After  
purg‐  
ing, in‐  
stall a  
new  
expan‐  
sion  
valve.  
92  
Rep. gr.00 - Technical data  
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...  
Air conditioning system with refrigerant R134a - Edition 10.2014  
lk  
Caddy 1996; Caddy 2004; Caddy 2011  
Vehicle Adapters re‐  
Adapters required for Miscella‐  
quired for refrig‐ refrigerant pipes to re‐ neous  
erant pipes to air ceiver  
conditioner com‐  
pressor  
Caddy ♦ Low-pres‐  
– Remove receiver  
and bridge refriger‐  
ant pipes.  
– Install  
1996 ►  
sure side  
adapter -  
adapt‐  
er -  
VAS 6338/4- ♦ Adapter - VAS  
VAS  
6338/28-  
6338/1  
9- in  
♦ High-pres‐  
sure side  
adapter -  
VAS 6338/2-  
or adapter -  
VAS  
♦ Adapter - VAS  
6338/29-  
place  
of ex‐  
pan‐  
– After flushing, in‐  
stall a new receiver.  
sion  
valve  
(or dril‐  
led out  
expan‐  
sion  
6338/14-  
valve  
e.g. 6N  
0 820  
679 C  
⇒ page  
71 )  
– After  
purg‐  
ing, in‐  
stall a  
new  
expan‐  
sion  
valve.  
Caddy ♦ Sanden /  
Receiver  
– Install  
adapt‐  
er -  
2004 ►;  
Caddy  
2011 ►  
Denso air  
– Can be flushed  
through.  
conditioner  
compressor  
VAS  
– After flushing, in‐  
stall a new receiver.  
6338/1  
8- in  
♦ Low-pres‐  
sure side  
adapter -  
VAS  
place  
of ex‐  
pan‐  
6338/12-  
sion  
valve  
(or a  
♦ High-pres‐  
sure side  
drilled  
out ex‐  
pan‐  
adapter -  
VAS 6338/3-  
sion  
♦ 7H0 820 803  
D air condi‐  
tioner com‐  
pressor  
valve  
⇒ page  
71 )  
♦ Low-pres‐  
sure side  
– After  
purg‐  
adapter -  
ing, in‐  
stall a  
new  
VAS 6338/7-  
♦ High-pres‐  
sure side  
expan‐  
sion  
adapter -  
valve.  
VAS 6338/2-  
7. Clearing refrigerant circuit of contaminants  
93  
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...  
Air conditioning system with refrigerant R134a - Edition 10.2014  
Polo 2010; Polo KH IN 2010; Polo KH IN 2015; Polo Lim IN 2011;  
Polo Lim RUS 2011; Polo KH MY 2014; Polo KH MY 2015; Polo  
Lim MY 2014; Polo 2014  
Vehicle Adapters re‐  
Adapters required for Miscella‐  
quired for refrig‐ refrigerant pipes to re‐ neous  
erant pipes to air ceiver  
conditioner com‐  
pressor  
Polo  
♦ Low-pres‐  
sure side  
adapter -  
VAS  
– Remove dryer car‐ – Install  
2010 ►;  
Polo KH  
IN 2010  
►; Polo  
HH IN  
2015;  
tridge and seal re‐  
ceiver.  
adapt‐  
er -  
VAS  
6338/12-  
– After flushing, in‐  
stall a new dryer  
cartridge.  
6338/3  
4- in  
♦ High-pres‐  
sure side  
place  
of ex‐  
pan‐  
Polo  
adapter -  
Lim IN  
2011 ►;  
Polo  
VAS 6338/3-  
sion  
valve  
(or a  
♦ For air condi‐  
tioner com‐  
Lim  
lk  
RUS  
drilled  
out ex‐  
pan‐  
pressors 6Q0  
820 808 F  
2011 ►;  
Polo KH  
MY  
and 6Q0 820  
808 G on high  
pressure side  
adapter -  
sion  
2014 ►;  
Polo KH  
MY  
valve  
⇒ page  
71 )  
VAS 6338/2-  
2015 ►;  
Polo  
– After  
Lim MY  
2014 ►;  
Polo  
purg‐  
ing, in‐  
stall a  
new  
2014 ►  
expan‐  
sion  
valve.  
94  
Rep. gr.00 - Technical data  
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...  
Air conditioning system with refrigerant R134a - Edition 10.2014  
Golf 1992; Vento 1992; Passat 1994  
Vehicle Adapters re‐  
Adapters required for Miscella‐  
quired for refrig‐ refrigerant pipes to re‐ neous  
erant pipes to air ceiver  
conditioner com‐  
pressor  
Golf  
Adapter - VAS  
– Remove receiver  
and bridge refriger‐  
ant pipes.  
– Install  
adapter  
- VAS  
6338/1  
9- in  
1992 ►, 6338/14-  
Vento  
1992 ►,  
♦ Adapter - VAS  
6338/28-  
Passat  
1994 ►  
place of  
expan‐  
sion  
♦ Adapter - VAS  
6338/29-  
valve  
– After flushing, in‐  
stall a new receiver.  
(or dril‐  
led out  
expan‐  
sion  
valve  
e.g. 6N  
0 820  
679 C  
⇒
pa  
ge 71 )  
– After  
purg‐  
ing, in‐  
stall a  
new ex‐  
pan‐  
sion  
valve.  
lk  
7. Clearing refrigerant circuit of contaminants  
95  
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...  
Air conditioning system with refrigerant R134a - Edition 10.2014  
Touran 2003; Golf 2004; Golf Plus 2005; Golf Plus 2009; Jetta  
2005; Eos 2006; Golf Variant 2007; Tiguan 2008; Scirocco 2009;  
Scirocco 2015; Golf 2009; Golf Variant 2010; Jetta 2011; Golf  
Cabrio 2012; NMS 2012; Beetle 2012; Golf 2013  
Vehicle Adapters re‐  
Adapters required for Miscella‐  
lk  
quired for refrig‐ refrigerant pipes to re‐ neous  
erant pipes to air ceiver  
conditioner com‐  
pressor  
Touran ♦ Low-pres‐  
There are two versions – Install  
2003 ►;  
Golf  
sure side  
adapter -  
VAS  
of the fluid receiver:  
See vehicle specific re‐  
pair manual.  
adapter  
- VAS  
6338/1  
8- in  
2004 ►;  
Golf  
6338/12-  
♦ Fluid receiver with  
permanently fitted  
dryer  
Plus  
place of  
expan‐  
sion  
♦ High-pres‐  
sure side  
2005 ►;  
Golf  
adapter -  
– Can be flushed  
through.  
Plus  
valve  
(or a  
VAS 6338/3-  
2009 ►;  
Jetta  
– After flushing, in‐  
stall a new receiver.  
♦ Receiver with dryer  
bag or cartridge  
drilled  
out ex‐  
pan‐  
2005 ►;  
Eos  
2006 ►;  
Golf  
sion  
valve  
⇒
– Remove dryer bag/  
cartridge and seal  
fluid receiver.  
Variant  
2007 ►;  
Tiguan  
2008 ►;  
Sciroc‐  
co 2009  
►; Scir‐  
occo  
pa  
ge 71 )  
– After purging, in‐  
stall a new dryer  
bag/cartridge.  
– After  
purg‐  
ing, in‐  
stall a  
new ex‐  
pan‐  
2015 ►;  
Golf  
2009 ►;  
Golf  
sion  
valve.  
Variant  
2010 ►;  
Jetta  
2011 ►;  
Golf  
Cabrio  
2012 ►;  
NMS  
2012  
►Beetle  
2012 ►  
96  
Rep. gr.00 - Technical data  
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...  
Air conditioning system with refrigerant R134a - Edition 10.2014  
Golf 2013; Golf Estate 2014; Golf 2014 (NAR); Golf SV 2015  
Vehicle Adapters re‐  
Adapters required for Miscella‐  
quired for refrig‐ refrigerant pipes to re‐ neous  
erant pipes to air ceiver  
conditioner com‐  
lk  
pressor  
Golf  
♦ Low-pres‐  
sure side  
adapter -  
VAS  
– Remove dryer bag/ – Install  
2013 ►;  
Golf Es‐  
tate  
cartridge and seal  
fluid receiver.  
adapter  
- VAS  
6338/3  
8- in  
2014 ►;  
Golf  
6338/12-  
– After purging, in‐  
stall a new dryer  
bag/cartridge.  
place of  
expan‐  
sion  
♦ High-pres‐  
sure side  
2014  
(NAR)  
►; Golf  
SV 2015  
►
adapter -  
– If a Showa con‐  
denser is fitted,  
valve  
(or a  
VAS 6338/3-  
leave the receiver  
fitted and purge the  
refrigerant circuit.  
drilled  
out ex‐  
pan‐  
sion  
– After flushing, in‐  
stall a new receiver.  
valve  
⇒
pa  
ge 71 )  
– After  
purg‐  
ing, in‐  
stall a  
new ex‐  
pan‐  
sion  
valve.  
Golf 1998; Golf Variant 1998; Vento 1999; New Beetle 1999; New  
Beetle Cabrio 2003; Bora 1999  
Golf  
♦ Low-pres‐  
sure side  
– Remove receiver  
and bridge refriger‐  
ant pipes.  
– Install  
adapter  
- VAS  
6338/1  
9- in  
1998 ►,  
Golf  
adapter -  
Variant  
1998 ►,  
Vento  
1999 ►,  
New  
VAS 6338/7-  
– Connect two adapt‐  
ers - VAS 6338/2-  
with hose - VAS  
♦ High-pres‐  
sure side  
place of  
expan‐  
sion  
adapter -  
6338/31- together.  
VAS 6338/2-  
Beetle  
1999 ►,  
New  
valve  
(or a  
– After flushing, in‐  
stall a new receiver.  
drilled  
out ex‐  
pan‐  
Beetle  
Cabrio  
2003 ►,  
Bora  
sion  
valve  
⇒
1999 ►  
pa  
ge 71 )  
– After  
purg‐  
ing, in‐  
stall a  
new ex‐  
pan‐  
sion  
valve.  
7. Clearing refrigerant circuit of contaminants  
97  
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...  
Air conditioning system with refrigerant R134a - Edition 10.2014  
Phaeton 2003  
Vehicle Adapters re‐  
lk  
Adapters required for Miscella‐  
quired for refrig‐ refrigerant pipes to re‐ neous  
erant pipes to air ceiver/reservoir  
conditioner com‐  
pressor  
Phaeton ♦ Low-pres‐  
– Remove reservoir – Restric‐  
2003 ►  
sure side  
adapter -  
VAS  
(dryer), and bridge  
refrigerant pipes.  
tor re‐  
moved  
and re‐  
friger‐  
6338/12-  
– Join two adapters -  
VAS 6338/6- and  
connect to hose -  
VAS 6338/31- .  
ant pipe  
recon‐  
nected.  
♦ High-pres‐  
sure side, 12,  
8 and 6-cyl.  
petrol en‐  
– After flushing, in‐  
stall a new reser‐  
voir.  
– After  
gines: adapt‐  
er - VAS  
flush‐  
ing, in‐  
stall a  
6338/2- .  
High-pres‐  
sure side, 10  
and 6-  
new re‐  
strictor.  
cyl. diesel en‐  
gines: adapt‐  
er - VAS  
6338/3-  
98  
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  
Passat 1997  
Vehicle Adapters re‐  
Adapters required for Miscella‐  
quired for refrig‐ refrigerant pipes to re‐ neous  
erant pipes to air ceiver/reservoir  
conditioner com‐  
pressor  
Passat ♦ Adapter -  
There are two versions – Restric‐  
1997 ►  
up to  
V.A.G  
of the reservoir.  
– Remove reservoir  
and bridge refriger‐  
ant pipes.  
tor re‐  
1785/7-  
moved  
and re‐  
friger‐  
Sep‐  
♦ Adapter -  
V.A.G  
tember  
2000  
ant line  
recon‐  
nected.  
1785/8-  
– Connect adapter -  
VAS 6338/9- and  
adapter - VAG  
♦ Low-pres‐  
sure side  
adapter -  
VAS  
1785/8- or adapter - – After  
VAS 6338/10- to  
hose - VAS  
flush‐  
ing, in‐  
stall a  
6338/12-  
6338/31- .  
new re‐  
strictor.  
♦ High-pres‐  
sure side  
– After flushing, in‐  
stall a new reser‐  
voir.  
adapter -  
VAS 6338/2-  
Passat ♦ Adapter -  
– Remove reservoir – Restric‐  
1997 ►  
from  
V.A.G  
and bridge refriger‐  
ant pipes.  
tor re‐  
1785/7-  
moved  
and re‐  
friger‐  
October  
2000  
♦ Adapter -  
V.A.G  
– Connect two adapt‐  
ers - VAS 6338/10-  
with hose - VAS  
ant line  
recon‐  
nected.  
1785/8-  
6338/31- together.  
♦ Low-pres‐  
sure side  
adapter -  
VAS  
– After flushing, in‐  
stall a new reser‐  
voir.  
– After  
flush‐  
ing, in‐  
stall a  
6338/12-  
new re‐  
strictor.  
♦ High-pres‐  
sure side  
adapter -  
VAS 6338/2-  
7. Clearing refrigerant circuit of contaminants  
99  
lk  
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...  
Air conditioning system with refrigerant R134a - Edition 10.2014  
Passat 2006; Passat CC 2009; CC 2010; Passat 2011; CC FL  
Vehicle Adapters re‐  
Adapters required for Miscella‐  
quired for refrig‐ refrigerant pipes to re‐ neous  
erant pipes to air ceiver/reservoir  
conditioner com‐  
pressor  
Passat ♦ Low-pres‐  
– Remove dryer car‐ – Install  
2006 ►,  
Passat  
CC  
sure side  
adapter -  
VAS  
tridge and seal re‐  
ceiver.  
adapter  
- VAS  
6338/1  
8- in  
2009 ►,  
CC  
6338/12-  
– After flushing, in‐  
stall a new dryer  
cartridge.  
place of  
expan‐  
sion  
♦ High-pres‐  
sure side  
2010 ►,  
Passat  
2011 ►,  
CC FL ►  
adapter -  
– If a Showa con‐  
denser is fitted,  
valve  
(or a  
VAS 6338/3-  
leave the receiver  
fitted and purge the  
refrigerant circuit.  
drilled  
out ex‐  
pan‐  
sion  
– After flushing, in‐  
stall a new receiver.  
valve  
⇒
pa  
ge 71 )  
– After  
purg‐  
ing, in‐  
stall a  
new ex‐  
pan‐  
sion  
valve.  
Passat 2015; Passat Estate 2015  
Note  
In the Passat 2015 and Passat Estate 2015 with BiTurbo engine,  
the refrigerant circuit is not flushed. In these vehicles, it would  
require too much effort to remove the expansion valve. If the air  
conditioner compressor is defective, check whether filings have  
entered the condenser or whether there are filings at the con‐  
denser outlet. If there are only filings on the inlet side but not on  
the outlet side, renew only the condenser and the air conditioner  
compressor.  
100  
Rep. gr.00 - Technical data  
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...  
Air conditioning system with refrigerant R134a - Edition 10.2014  
lk  
Vehicle Adapters re‐  
Adapters required for Miscella‐  
quired for refrig‐ refrigerant pipes to re‐ neous  
erant pipes to air ceiver  
conditioner com‐  
pressor  
Passat ♦ Low-pres‐  
– Remove desiccant – Install  
2015 ►;  
Passat  
Estate  
2015 ►  
sure side  
adapter -  
VAS  
bag/cartridge and  
seal fluid receiver.  
adapter  
- VAS  
6338/1  
8- in  
6338/12-  
– After purging, in‐  
stall a new desic‐  
cant bag/cartridge.  
place of  
expan‐  
sion  
♦ High-pres‐  
sure side  
adapter -  
valve  
(or a  
VAS 6338/3-  
drilled  
out ex‐  
pan‐  
sion  
valve  
⇒
pa  
ge 71 )  
– After  
purg‐  
ing, in‐  
stall a  
new ex‐  
pan‐  
sion  
valve.  
Sharan 1996  
Note  
On vehicles with a 2nd evaporator (Sharan), the front and rear  
refrigerant circuit must be rinsed separately. The front refrigerant  
circuit must be sealed with adapter - V.A.G 1785/1- , adapter -  
1785/3- and sealing caps -VAS 6338/30-.  
7. Clearing refrigerant circuit of contaminants  
101  
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 and 2nd evapo‐  
conditioner com‐ rator  
pressor  
Sharan ♦ Low-pressure – Remove receiver  
– Install  
adapt‐  
er -  
1996 ►  
up to  
May  
side adapter -  
VAS 6338/7-  
and connect refrig‐  
erant pipes to  
adapter - VAS  
VAS  
♦ High-pressure  
side adapter -  
VAS 6338/2-  
2000  
6338/37- .  
6338/3  
5- in  
– After purging, in‐  
stall a new receiver  
(dryer).  
place  
of front  
and  
♦ or adapter -  
VAS 6338/14-  
♦ Low-pressure line  
for second evapo‐  
rator adapter -  
rear  
expan‐  
sion  
V.A.G 1785/7-  
valves  
(or a  
♦ High-pressure line  
for second evalpko‐  
rator adapter -  
drilled  
out ex‐  
pan‐  
V.A.G 1785/5-  
sion  
♦ Adapter - V.A.G  
1785/3- with seal‐  
ing cap -VAS  
valve  
⇒ page  
71 )  
6338/30- to seal  
front refrigerant cir‐  
cuit.  
– After  
purg‐  
ing, in‐  
stall a  
new  
♦ Adapter - V.A.G  
1785/1- with seal‐  
ing cap -VAS  
expan‐  
sion  
6338/30- to seal  
front refrigerant cir‐  
cuit.  
valve.  
Sharan ♦ Low-pressure – Remove dryer car‐ – Install  
1996 ►  
from  
side adapter -  
VAS 6338/7-  
tridge and seal re‐  
ceiver.  
adapt‐  
er -  
June  
2000  
– After flushing, in‐  
stall a new dryer  
cartridge.  
VAS  
♦ High-pressure  
side adapter -  
VAS 6338/2-  
6338/3  
5- in  
♦ Low-pressure line  
for second evapo‐  
rator adapter -  
place  
of front  
and  
V.A.G 1785/7-  
rear  
expan‐  
sion  
♦ High-pressure line  
for second evapo‐  
rator adapter -  
valves  
(or a  
V.A.G 1785/5-  
drilled  
out ex‐  
pan‐  
♦ Adapter - V.A.G  
1785/3- with seal‐  
ing cap -VAS  
sion  
valve  
⇒ page  
71 )  
6338/30- to seal  
front refrigerant cir‐  
cuit.  
– After  
♦ Adapter - V.A.G  
1785/1- with seal‐  
ing cap -VAS  
purg‐  
ing, in‐  
stall a  
new  
6338/30- to seal  
front refrigerant cir‐  
cuit.  
expan‐  
sion  
valve.  
102  
Rep. gr.00 - Technical data  
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...  
Air conditioning system with refrigerant R134a - Edition 10.2014  
Sharan 2011  
Note  
On vehicles with a 2nd evaporator (Sharan), the front and rear  
refrigerant circuit must be rinsed separately. The front refrigerant  
circuit must be sealed with adapter - V.A.G 1785/1- , adapter -  
1785/3- and sealing caps -VAS 6338/30-.  
lk  
Vehicle Adapters re‐  
Adapters required for Miscella‐  
quired for refrig‐ refrigerant pipes to re‐ neous  
erant pipes to air ceiver and 2nd evapo‐  
conditioner com‐ rator  
pressor  
Sharan ♦ Low-pressure – Remove dryer car‐ – Install  
2011 ►  
side adapter -  
VAS 6338/12-  
tridge and seal re‐  
ceiver.  
adapt‐  
er -  
– After flushing, in‐  
stall a new dryer  
cartridge.  
VAS  
♦ High-pressure  
side adapter -  
VAS 6338/3-  
6338/1  
8- in  
♦ Low-pressure line  
for second evapo‐  
rator adapter - VAS  
6338/3-  
place  
of front  
expan‐  
sion  
valve  
(or a  
♦ High-pressure line  
for 2nd evaporator  
adapter - VAS  
6338/4-  
drilled  
out ex‐  
pan‐  
sion  
♦ The refrigerant  
lines to the second  
evaporator must be  
loosened sufficient‐  
ly so that the adapt‐  
er can be fitted  
without deforming  
the refrigerant  
valve  
⇒ page  
71 )  
– Install  
adapt‐  
er -  
VAS  
lines.  
6338/3  
3- in  
♦ Sealing adapter -  
VAS 6338/5- for  
front refrigerant cir‐  
cuit.  
place  
of rear  
expan‐  
sion  
♦ Sealing adapter -  
VAS 6338/11- for  
front refrigerant cir‐  
cuit.  
valve  
(or a  
drilled  
out ex‐  
pan‐  
sion  
valve  
⇒ page  
71 )  
– After  
purg‐  
ing, in‐  
stall a  
new  
expan‐  
sion  
valve.  
7. Clearing refrigerant circuit of contaminants  
103  
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...  
Air conditioning system with refrigerant R134a - Edition 10.2014  
Touareg 2003; Touareg 2010; Touareg 2015; Touareg Hybrid  
2010  
Note  
On vehicles with a second evaporator (Touareg), the front and  
rear refrigerant circuit must be purged separately. The front re‐  
frigerant circuit must be sealed with sealing adapter - VAS  
6338/5- and sealing adapter - VAS 6338/11- .  
lk  
104  
Rep. gr.00 - Technical data  
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 and second  
conditioner com‐ evaporator  
pressor  
Touar‐ ♦ Low-pressure – Remove dryer car‐ – Install  
eg  
side adapter -  
VAS 6338/12-  
tridge and seal re‐  
ceiver.  
adapt‐  
er -  
2003 ►  
to vehi‐  
cle  
– After flushing, in‐  
stall a new dryer  
cartridge.  
VAS  
♦ High-pressure  
side adapter -  
VAS 6338/2-  
6338/1  
7- in  
identifi‐  
cation  
number  
50000  
♦ Low-pressure line  
for second evapo‐  
place  
of front  
expan‐  
sion  
♦ Engine code  
BJN 6.0 l to  
lk  
rator adapter - VAS  
6338/3-  
vehicle identi‐  
fication num‐  
ber 20000 on  
high-pressure  
side adapter -  
VAS 6338/3-  
valve  
(or a  
♦ High-pressure line  
for second evapo‐  
rator adapter - VAS  
6338/4-  
drilled  
out ex‐  
pan‐  
sion  
♦ Sealing adapter -  
VAS 6338/5- for  
front refrigerant cir‐  
cuit.  
valve  
⇒ page  
71 )  
– After  
♦ Sealing adapter -  
VAS 6338/11- for  
front refrigerant cir‐  
cuit.  
purg‐  
ing, in‐  
stall a  
new  
expan‐  
sion  
valve.  
– Drill  
out ex‐  
pan‐  
sion  
valve  
at sec‐  
ond  
evapo‐  
rator  
⇒ page  
71 .  
– After  
purg‐  
ing, in‐  
stall a  
new  
expan‐  
sion  
valve.  
7. Clearing refrigerant circuit of contaminants  
105  
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...  
Air conditioning system with refrigerant R134a - Edition 10.2014  
lk  
Vehicle Adapters re‐  
Adapters required for Miscella‐  
quired for refrig‐ refrigerant pipes to re‐ neous  
erant pipes to air ceiver and second  
conditioner com‐ evaporator  
pressor  
Touar‐ ♦ Low-pressure – Remove dryer car‐ – Install  
eg  
side adapter -  
VAS 6338/12-  
tridge and seal re‐  
ceiver.  
adapt‐  
er -  
2003 ►  
as of  
– After flushing, in‐  
stall a new dryer  
cartridge.  
VAS  
♦ High-pressure  
side adapter -  
VAS 6338/2-  
or adapter -  
vehicle  
identifi‐  
cation  
number  
50001;  
Touar‐  
eg  
6338/1  
7- or  
♦ Low-pressure line  
for second evapo‐  
rator adapter - VAS  
6338/3-  
adapt‐  
er -  
VAS 6338/3-  
VAS  
6338/3  
3- in  
♦ Electrical air  
conditioner  
♦ High-pressure line  
for second evapo‐  
rator adapter - VAS  
6338/4-  
2010 ►;  
Touar‐  
eg  
place  
of front  
and  
compressor,  
adapter - VAS  
6338/40- and  
adapter - VAS  
6338/41-  
2015;  
Touar‐  
eg Hy‐  
brid  
rear  
expan‐  
sion  
♦ Sealing adapter -  
VAS 6338/5- for  
front refrigerant cir‐  
cuit.  
valves  
(or a  
2010 ►  
drilled  
out ex‐  
pan‐  
♦ Sealing adapter -  
VAS 6338/11- for  
front refrigerant cir‐  
cuit.  
sion  
valve  
⇒ page  
71 )  
– After  
purg‐  
ing, in‐  
stall  
new  
expan‐  
sion  
valves.  
Transporter 1991  
Note  
On vehicles with a second evaporator, the front and rear refrig‐  
erant circuit must be purged separately. The front refrigerant  
circuit must be sealed with sealing adapter - VAS 6338/5- and  
sealing adapter - VAS 6338/11- .  
106  
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 and second  
conditioner com‐ evaporator  
pressor  
Trans‐ ♦ Air condition‐ • If the receiver is at‐ – Install  
porter  
1991 ►  
to  
er compres‐  
sor 2D0 820  
805 B and  
701 820 805  
Q adapter -  
VAS  
tached beneath the  
condenser, it can  
be purged.  
adapt‐  
er -  
VAS  
12.1995  
6338/5  
5- in  
– For other versions,  
remove reservoir.  
♦ Adapter - VAS  
6338/20- for receiv‐  
er.  
place  
of front  
and  
6338/54-  
♦ Vehicle with a  
additional  
evaporator  
on the roof,  
use adapter -  
VAS  
rear  
expan‐  
sion  
♦ Adapter - VAS  
6338/29- for receiv‐  
er.  
valves  
(or a  
drilled  
out ex‐  
pan‐  
♦ Adapter - VAS  
6338/26- with seal‐  
ing cap -VAS  
6338/51- and  
adapter -  
VAS  
sion  
6338/30- to seal  
front refrigerant cir‐  
cuit.  
6338/52- .  
valve  
⇒ page  
71 )  
♦ Adapter - VAS  
6338/27- with seal‐  
ing cap -VAS  
– After  
purg‐  
ing, in‐  
stall a  
new  
6338/30- to seal  
front refrigerant cir‐  
cuit.  
expan‐  
sion  
♦ Adapter - VAS  
6338/57- for refrig‐  
erant line of second  
evaporator.  
valve.  
♦ Adapter - VAS  
6338/58- for refrig‐  
erant line of second  
evaporator.  
– After flushing, in‐  
stall a new receiver.  
7. Clearing refrigerant circuit of contaminants  
107  
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 and second  
conditioner com‐ evaporator  
pressor  
Trans‐ ♦ Air condition‐ • If the receiver is at‐ – Install  
porter  
1991 ►  
from  
er compres‐  
sor 7D0 820  
805 E adapt‐  
er - VAS  
tached beneath the  
condenser, it can  
be purged.  
adapt‐  
er -  
VAS  
Jan.  
6338/5  
5- in  
– For other versions,  
remove reservoir.  
1996  
6338/53-  
place  
of front  
and  
♦ Air condition‐ ♦ Adapter - VAS  
er compres‐  
sor 7D0 820  
805 H low-  
pressure side  
adapter -  
6338/20- for receiv‐  
er.  
rear  
expan‐  
sion  
♦ Adapter - VAS  
6338/29- for receiv‐  
er.  
valves  
(or a  
VAS 6338/7-  
drilled  
out ex‐  
pan‐  
♦ Adapter - VAS  
6338/26- with seal‐  
ing cap -VAS  
♦ High-pres‐  
sure side  
adapter -  
sion  
6338/30- to seal  
front refrigerant cir‐  
cuit.  
VAS 6338/2-  
valve  
⇒ page  
71 )  
♦ Vehicle with a  
additional  
evaporator  
on the roof,  
use adapter -  
VAS  
♦ Adapter - VAS  
6338/27- with seal‐  
ing cap -VAS  
– After  
purg‐  
ing, in‐  
stall a  
new  
lk  
6338/30- to seal  
front refrigerant cir‐  
cuit.  
6338/51- and  
adapter -  
expan‐  
sion  
VAS  
♦ Adapter - VAS  
6338/57- for refrig‐  
erant line of second  
evaporator.  
6338/52- .  
valve.  
♦ Adapter - VAS  
6338/58- for refrig‐  
erant line of second  
evaporator.  
– After flushing, in‐  
stall a new receiver.  
Transporter 2004  
Note  
On vehicles with a second evaporator, the front and rear refrig‐  
erant circuit must be purged separately. The front refrigerant  
circuit must be sealed with sealing adapter - VAS 6338/5- and  
sealing adapter - VAS 6338/11- .  
108  
Rep. gr.00 - Technical data  
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 and second  
conditioner com‐ evaporator  
pressor  
Trans‐ ♦ Air condition‐ – Remove dryer car‐ – To ve‐  
porter  
7H 2004  
►
er compres‐  
sor 7H0 820  
805 E low-  
pressure side  
adapter -  
tridge and seal re‐  
ceiver.  
hicle  
identi‐  
fica‐  
tion  
– After flushing, in‐  
stall a new dryer  
cartridge.  
num‐  
ber  
lk  
VAS  
♦ Sealing adapter -  
VAS 6338/5- for  
front refrigerant cir‐  
cuit.  
6338/12- ,  
high-pres‐  
sure side  
20000  
, drill  
out  
adapter -  
ex‐  
♦ Sealing adapter -  
VAS 6338/11- for  
front refrigerant cir‐  
cuit.  
VAS 6338/3-  
pan‐  
sion  
valve  
⇒
♦ Air condition‐  
er compres‐  
sor 7H0 820  
803 C low-  
pressure side  
adapter -  
page  
71  
♦ Low-pressure line  
for second evapo‐  
rator adapter - VAS  
6338/3-  
– From  
vehi‐  
cle  
VAS 6338/7- ,  
high-pres‐  
♦ High-pressure line  
for second evapo‐  
rator adapter - VAS  
6338/4-  
sure side  
identi‐  
fica‐  
tion  
adapter -  
VAS 6338/2-  
num‐  
ber  
20001  
, in‐  
stall  
adapt‐  
er -  
VAS  
6338/  
56- in  
place  
of  
front  
ex‐  
pan‐  
sion  
valve  
– After  
purg‐  
ing, in‐  
stall a  
new  
ex‐  
pan‐  
sion  
valve.  
– Install  
adapt‐  
er -  
VAS  
6338/  
33- in  
place  
of ex‐  
pan‐  
sion  
valve  
on  
7. Clearing refrigerant circuit of contaminants  
109  
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 and second  
conditioner com‐ evaporator  
pressor  
sec‐  
ond  
evap‐  
orator  
– After  
purg‐  
ing, in‐  
stall a  
new  
ex‐  
pan‐  
sion  
valve.  
110  
Rep. gr.00 - Technical data  
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 and second  
conditioner com‐ evaporator  
pressor  
Trans‐ ♦ Air condition‐ – Remove dryer car‐ – To ve‐  
porter  
7J 2004  
►
er compres‐  
sor 7H0 820  
805 E low-  
pressure side  
adapter -  
tridge and seal re‐  
ceiver.  
hicle  
identi‐  
fica‐  
tion  
– After flushing, in‐  
stall a new dryer  
cartridge.  
num‐  
ber  
VAS  
♦ Sealing adapter -  
VAS 6338/5- for  
front refrigerant cir‐  
cuit.  
6338/12- ,  
high-pres‐  
sure side  
5000,  
drill  
out  
adapter -  
ex‐  
♦ Sealing adapter -  
VAS 6338/11- for  
front refrigerant cir‐  
cuit.  
VAS 6338/3-  
pan‐  
sion  
valve  
⇒
♦ Air condition‐  
er compres‐  
sor 7H0 820  
803 C low-  
pressure side  
adapter -  
page  
71  
♦ Low-prelsksure line  
for second evapo‐  
rator adapter - VAS  
6338/3-  
– From  
vehi‐  
cle  
VAS 6338/7- ,  
high-pres‐  
♦ High-pressure line  
for second evapo‐  
rator adapter - VAS  
6338/4-  
sure side  
identi‐  
fica‐  
adapter -  
VAS 6338/2-  
tion  
num‐  
ber  
♦ Air condition‐  
er compres‐  
sor 7H0 820  
805 D low-  
pressure side  
adapter -  
5001,  
install  
adapt‐  
er -  
VAS  
6338/  
56- in  
place  
of  
VAS  
6338/52- ,  
high-pres‐  
sure side  
adapter -  
front  
ex‐  
VAS  
6338/51-  
pan‐  
sion  
valve  
– After  
purg‐  
ing, in‐  
stall a  
new  
ex‐  
pan‐  
sion  
valve.  
– Install  
adapt‐  
er -  
VAS  
6338/  
56- in  
place  
of ex‐  
pan‐  
sion  
valve  
on  
sec‐  
7. Clearing refrigerant circuit of contaminants  
111  

Related Topics

7.1 Blowing through refrigerant circuit... 7.2 Purging (cleaning) refrigerant circuit with R134a

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