Get Generalnotesonairconditioningsystems -> 1.12 Basics for working on refrigerant circuit Guide for Volkswagen LT Van Second Generation (1996-2006)

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Under no circumstances may refrigerant be charged into systems

or vessels containing air.

Precautions:

– Evacuate systems and containers before charging with refrig‐

erant.

1.12

Basics for working on refrigerant circuit

•

Observe instructions specific to the workplace; ⇒ Volkswagen

ServiceNet; Handbooks; Service handbook; Environmental

protection . Refrigerant from air conditioning systems / refrig‐

erant oils - to be displayed at refrigerant designated working

area.

•

Observe the utmost cleanliness when working.

When handling refrigerants and nitrogen, wear protective

clothing, protective glasses and protective gloves.

•

Switch on exhaust gas fume extractor (if there is one).

Extract the refrigerant circuit using only the air conditioner

service station, and only then loosen the threaded joints and

renew the defective components.

•

Protect units and hoses against moisture and dirt using sealing

caps.

Use only tools and materials that are intended for use with

refrigerant R134a.

Protect refrigerant oil by sealing container to prevent ingress

of moisture.

– Blow through refrigerant circuit with compressed air and nitro‐

gen ⇒ page 65 :

– Purge refrigerant circuit with refrigerant R134a. ⇒ page 67

In vehicles that have an air conditioner compressor without a

magnetic clutch:

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Note

♦ If the engine is being started for the first time after the refrig‐

erant circuit has been reassembled.

♦ If possible, start engine only with refrigerant circuit charged.

♦ The air conditioner compressor is driven permanently by the

poly V-belt pulley or elastic drive coupling (it is not fitted with

a magnetic clutch).

♦ If an air conditioner compressor seizes, the overload protec‐

tion separates from the air conditioner compressor shaft. Even

if no bulges are visible in the V-belt pulley or overload protec‐

tion, it may be that the air conditioner compressor has seized.

Another indication is abraded rubber material around the poly

V-belt pulley or overload protection.

♦ The air conditioner compressor has an internal oil circuit to

ensure that the air conditioner compressor is not damaged

when the refrigerant circuit is empty. This means that about

40 to 50 cm refrigerant oil remain in the air conditioner com‐

pressor.

♦ The engine may be started only when the refrigerant circuit is

properly assembled. If, for example, the refrigerant lines are

not connected to the air conditioner compressor and the en‐

gine is running, the compressor may heat up so much through

internal warming that it will be destroyed.

♦ The air conditioner compressor regulating valve - N280- is not

activated when the refrigerant circuit is empty and the air con‐

ditioner compressor idles with the engine.

♦ If it is necessary to start engine with an empty refrigerant cir‐

cuit:

♦ The refrigerant circuit must be fully assembled.

♦ At least ¼ of the quantity of refrigerant oil specified for this

refrigerant circuit must be in the air conditioner compressor.

♦ The engine speed must not exceed 2000 rpm.

♦ The engine should run < 10 minutes.

1.12.1

O-ring

♦ Use only O-rings that are resistant to refrigerant R134a and

related refrigerant oils. O-rings are no longer colour-coded.

Coloured and black O-rings are used.

♦ Check that the O-rings used have the correct internal diame‐

ters.

⇒ Rep. gr. 87

⇒ Parts catalogue

♦ Never reuse O-rings.

♦ Before installing, moisten O-rings lightly with refrigerant oil

(PAG oil).

1. General notes on air conditioning systems

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Note

♦ When purging components with compressed air and nitrogen,

always collect the gas mixture exiting the component with suit‐

able exhaust gas extraction equipment (workshop fume ex‐

tractor).

♦ After completing repair work, screw sealing caps (with seals)

onto valve and service connections.

Before operating the air conditioning system. Check the vehicle-

specific charge quantities ⇒ Rep. gr. 87 .

Do not top up a charged refrigerant circuit; discharge refrigerant

present and recharge system.

1.12.2

Before operating the air conditioning

system after recharging with refrigerant

– After installing a new air conditioner compressor or filling with

fresh refrigerant oil (e.g. after blowing out refrigerant circuit),

turn compressor pulley 10 revolutions by hand before starting

engine. This will prevent damage to^lt^khe air conditioner com‐

pressor.

– On 5-cyl. or 10-cyl. diesel engine, turn air conditioner com‐

pressor at overload protection 10 times by hand. Then install

compressor. This will prevent damage to the air conditioner

compressor.

– Start the engine with the air conditioning system switched off

(the air conditioning system magnetic clutch - N25- and the air

conditioner compressor regulating valve - N280- are not acti‐

vated).

– After the engine has stabilised at its idling speed, switch on

the air conditioner compressor and allow the engine to idle for

at least 10 minutes at maximum cooling power.

Rep. gr.00 - Technical data

Generalnotesonairconditioningsystems -> 1.12 Basics for working on refrigerant circuit for Your Volkswagen LT Van Second Generation (1996-2006)

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