Get Detectingleaksinrefrigerantcircuit -> 6.3 Detecting leaks... using leak detecting system VAS 6196... 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

6.3

Detecting leaks in refrigerant circuit us‐

ing leak detecting system - VAS 6196-

or leak detecting system - VAS 6201- or

a later model

Note

Small leaks can be detected with, for example, an UV leak de‐

tector additive.

– Evacuate refrigerant circuit using an air conditioner service

station ⇒ page 50 .

Note

♦ If a larger leak is detected during the evacuation process, de‐

termine cause and rectify as described ⇒ page 50 .

♦ If during the evacuation process no leak is detected or a very

small leak is detected that but cannot be located, proceed as

follows ⇒ page 56 .

♦ Refrigerant gas is quickly dispersed by air motion. Therefore

drafts must be avoided during a search for leaks.

♦ If the refrigerant circuit is completely empty, charge with about

10% of refrigerant capacity (sticker R134a or vehicle-specific

workshop manual).

lk

Leak detecting system - VAS 6196-

or

Leak detecting system - VAS 6201- or later model

1 - Hand pump with low-pressure service hose, service cou‐

pling and non-return valve - VAS 6201/1-

2 - Cartridge - VAS 6201/2-

3 - Cleaning solution - VAS 6201/3-

4 - UV leakage detector lamp - VAS 6201/4-

5 - UV absorbing eye protection - VAS 6201/6-

6 - Label - VAS 6201/7-

7 - Tube

VAS 6201/8

8 - Protective gloves - VAS 6201/9-

6. Detecting leaks in refrigerant circuit

59

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Injecting leak detecting additive to an empty refrigerant circuit

lk

The cartridge -A- contains 15.4 ml of leak detecting additive (one

unit -B- equates to 2.5 ml).

– Assemble hand pump - VAS 6201- item -1- and cartridge item

-2- -VAS 6201/2- .

– Connect filler hose - VAS 6201/8- ( ⇒ page 59 item -7-) to hand

pump.

– Open service valve of hand pump.

60

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

The leak detecting additive can be injected into the empty refrig‐

erant circuit via an open circuit connection.

– Open an easily assessable connection in the refrigerant cir‐

cuit.

– Cover area of connection with foil or absorbent paper.

– Hold tube upwards

– Turn T-bar of hand pump until the leak detecting additive flows

out of the tube.

3

–

Inject 2.5 ± 0.5 ml (millilitre = cm ) of leak detecting additive

into the refrigerant circuit.

Note

Note the following, if a leak detecting additive has been injecte_ld_k

during a previous repair of the refrigerant circuit, only inject new

leak detecting additive if the refrigerant machine oil has been re‐

placed. If only some of the refrigerant machine oil was replaced

then only the respective amount of leak detecting additive should

be injected. If for example 100 ml of machine oil was replaced on

a vehicle with 250 ml of refrigerant machine oil, inject only 1 ml

3

(cm ) of leak detecting additive.

– Renew O-rings at opened connection.

– Reassemble refrigerant circuit again.

– Attach a label, close to the service connection, which has in‐

formation showing that the refrigerant circuit has been injected

with a leak detecting additive.

– Evacuate and fill the refrigerant circuit as per specifications

⇒ page 51 and ⇒ page 50 .

– Start air conditioning system.

Note

The air conditioning system must be operated for at least 60 mi‐

nutes to ensure that the injected leak detecting additive is distrib‐

uted throughout the entire refrigerant circuit (air conditioner

compressor must run). The leak may become visible after a short

period, but this depends on the size of the leak.

– Use UV lamp VAS 6196/4 to search for the leak in the refrig‐

erant circuit ⇒ page 63 .

Note

Using cleaning solution - VAS 6201/3- , clean the engine com‐

partment and, if necessary, the components of the refrigerant

circuit, to remove leak detection additive residue left from the re‐

pair work.

6. Detecting leaks in refrigerant circuit

61

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Injecting leak detecting additive to a charged refrigerant circuit

Note

♦ Note the following, if a leak detecting additive has been injec‐

ted during a previous repair of the refrigerant circuit, only inject

new leak detecting additive if the refrigerant machine oil has

been replaced. If only some of the refrigerant machine oil was

replaced then only the respective amount of leak detecting

additive should be injected. If for example 100 ml of machine

oil was replaced on a vehicle with 250 ml of refrigerant ma‐

3

chine oil, inject only 1 ml (cm ) of leak detecting additive.

♦ A small amount of leak detecting additive remains in the serv‐

ice connection. Carefully remove the remains as this will help

to prevent these remains being falsely identified as a leak

when leak detection is carried out in the future.

The cartridge -A- contains 15.4 ml of leak detecting additive (one

unit -B- equates to 2.5 ml).

lk

– Switch off ignition.

– Remove sealing cap from service connection on the low-pres‐

sure side of the refrigerant circuit.

– Assemble hand pump - VAS 6201- item -1- and cartridge item

-2- -VAS 6201/2- .

Note

Ensure the hose of the hand pump is completely filled with leak

detecting additive.

– Fit the quick release coupling to the service connection of the

low-pressure side and open the service coupling by turning the

hand wheel. Hold hose upwards and turn T-bar of hand pump

until the leak detecting additive starts to flow out of the tube.

– Cover area of service connection on vehicle with foil or ab‐

sorbent paper.

– Turn T-bar of hand pump and inject 2.5 ± 0.5 ml (millilitre =

3

cm ) of leak detecting additive into the refrigerant circuit.

62

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

– Close the service coupling and remove it from the service

connection.

– Remove the remains of the leak detecting additive from the

service connection, with for example, absorbent paper.

– Seal service connection using the sealing cap.

– If necessary, clean the area of the service connection using

the cleaning solution.

lk

– Attach a label, close to the service connection, which has in‐

formation showing that the refrigerant circuit has been injected

with a leak detecting additive.

– Start air conditioning system.

Note

The air conditioning system must be operated for at least 60 mi‐

nutes to ensure that the injected leak detecting additive is distrib‐

uted throughout the entire refrigerant circuit (air conditioner

compressor must run). The leak may become visible after a short

period, but this depends on the size of the leak.

– Use UV lamp VAS 6196/4 to search for the leak in the refrig‐

erant circuit ⇒ page 63 .

Note

Using cleaning solution - VAS 6201/3- , clean the engine com‐

partment and, if necessary, the components of the refrigerant

circuit, to remove leak detection additive residue left from the re‐

pair work.

Searching for leaks in the refrigerant circuit using UV lamp VAS

6196/4

WARNING

Do not look into the UV lamp.

Do not point the UV lamp at another person.

6. Detecting leaks in refrigerant circuit

63

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Note

♦ The air conditioning system must be operated for at least

60 minutes to ensure that the injected leak detecting additive

is distributed throughout the entire refrigerant circuit (air con‐

ditioner compressor must run). The leak may become visible

after a short period, but this depends on the size of the leak.

♦ For leaks on the evaporator, the additive can wash off with the

condensed water and leak out from the condensed water

drain-off. As the evaporator is not accessible on the majority

of models without a great amount of pre-preparation, a check

of the condensed water drain point can indicate a leaking

evaporator. The additive must have been in the refrigerant cir‐

cuit for a long time to make this possible.

♦ The eye protect is not only required to protect the eyes, it also

amplifies the illumination of the additive under the UV lamp.

♦ Independent of the accessibility to the various components of

the refrigerant circuit, it may become necessary to remove

certain components from the vehicle (e.g. bumper or air filter).

– Position the vehicle in a darker area of the workshop (in day‐

light or under strong lighting the effect of the UV lamp is greatly

lk

reduced).

– Check the accessibility to the various components of the re‐

frigerant circuit and remove components in the vicinity of the

refrigerant circuit that obstruct the view of the respective circuit

components (e.g. sound insulation and bumper).

– Protect eyes with protective glasses.

– Connect UV lamp to a 12 V battery (vehicle battery). Ensure

that it is connected to the correct terminals.

– Switch on UV lamp and illuminate components of the refriger‐

ant circuit. Locations where leaking refrigerant along with

refrigerant oil and leak detecting additive can leak out, light-up

(fluorinate) under UV light.

Note

♦ The leak detection additive can be allowed to remain in the

refrigerant circuit.

♦ Using cleaning solution - VAS 6201/3- , clean the engine com‐

partment and, if necessary, the components of the refrigerant

circuit, to remove leak detection additive residue left from the

repair work.

64

Rep. gr.00 - Technical data

Detectingleaksinrefrigerantcircuit -> 6.3 Detecting leaks... using leak detecting system VAS 6196... for Your Volkswagen LT Van Second Generation (1996-2006)

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