Get Renewingcomponents 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

11

Renewing components

•

All components of the refrigerant circuit submitted for quality

monitoring must always be sealed (use the original sealing

caps from the genuine part).

•

The genuine parts (air conditioner compressor, reservoir, re‐

ceiver, evaporator and condenser) are charged with nitrogen

before shipment. This filling is being gradually discontinued,

the pressure of the nitrogen filling is so low that escaping gas

is no longer perceptible when the part is initially opened.

•

Where vehicles are fitted with an air conditioner compressor

without a magnetic clutch, the engine should be started only

when the refrigerant circuit has been fully assembled (since

the air conditioner compressor will always run when the engine

is running) ⇒ page 14 .

lk

The air conditioner compressor with air conditioner compres‐

sor regulating valve - N280- (without magnetic clutch) has an

internal oil circuit to ensure that the air conditioner compressor

is not damaged when the refrigerant circuit is empty. This

3

means that approx. 40 to 50 cm of refrigerant oil remains in

the air conditioner compressor ⇒ page 14 .

Note

♦ Since genuine parts are sometimes stored for long periods in

various places, it can well be that gas will escape from some

parts when first opened but not from others (even among those

having the same part number). Therefore, be careful when

unscrewing the sealing plugs from the genuine part connec‐

tions and allow the nitrogen gas to escape slowly.

♦ Either a restrictor with a reservoir or an expansion valve with

a receiver is built into the refrigerant circuit.

♦ Seal open connections and lines to prevent moisture from en‐

tering.

♦ Always renew restrictor.

The reservoir or receiver or cartridge of the dryer bag need not

be renewed under the following circumstances:

•

After an accident in which there was no damage to the reser‐

voir or receiver.

•

Repairs are performed quickly (no more delay than during a

normal repair time) and there was no moisture intrusion. The

vehicle is no more than 5 years old.

The reservoir or receiver or dryer cartridge should be renewed

under the following circumstances:

•

The refrigerant circuit was opened and the vehicle is more than

5 years old.

The refrigerant circuit has been opened for in indeterminate

period (seepage leak).

Repairs take longer than a normal repair time and there has

been moisture intrusion.

Always renew collector/reservoir or dryer cartridge after blow‐

ing through with compressed air or purging with refrigerant

R134a. Keep genuine parts sealed for as long as possible to

keep the ingress of moisture as low as possible.

•

The air conditioner compressor seizes.

11. Renewing components

159

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Air conditioning system with refrigerant R134a - Edition 10.2014

•

The reservoir or receiver is damaged (e.g. in an accident).

Caution

♦ Handling refrigerant ⇒ Volkswagen ServiceNet; Service

handbook; Environmental protection; Waste disposal;

Current situation; Disposal channels; Disposal of used

oils; Refrigerant oils .

lk

11.1

In the event of leaking or damaged com‐

ponents (apart from the air conditioner

compressor, receiver or reservoir)

11.1.1

If the refrigerant circuit was completely

empty

– Remove defective part.

– Remove air conditioner compressor.

– Remove oil drain screw from air conditioner compressor.

Note

♦ To speed up the draining of the refrigerant oil, rotate the shaft

of the air conditioner compressor by hand using the poly V-

belt pulley or the magnetic clutch.

♦ Pour old refrigerant oil out of air conditioner compressor, han‐

dling refrigerant oil ⇒ Volkswagen ServiceNet; Service hand‐

book; Environmental protection; Waste disposal; Current

situation; Disposal channels; Disposal of used oils; Refrigerant

oils .

♦ Then fill the air conditioner compressor with the quantity of

new refrigerant oil corresponding to the quantity in a genuine

air conditioner compressor ⇒ Rep. gr. 87 .

♦ Different types and quantities of refrigerant oils are required

for different air conditioner compressors ⇒ Rep. gr. 87 .

♦ To ensure proper lubrication of the air conditioner compressor

when it runs for the first time, the air conditioner compressor

3

must be filled with at least 80 cm of refrigerant oil; the re‐

mainder can be poured into the new reservoir or receiver ⇒

Rep. gr. 87 .

♦ If dirt enters the air conditioner compressor whilst the refrig‐

erant circuit is open (e.g. after an accident), the air conditioner

compressor should be renewed.

♦ Blow through refrigerant circuit with compressed air and re‐

move moisture with nitrogen ⇒ page 65 .

– Renew receiver or reservoir and restrictor.

– Assemble the refrigerant circuit, evacuate it and charge it.

11.1.2

If there is still refrigerant in the refriger‐

ant circuit

– Drain refrigerant circuit.

160

Rep. gr.00 - Technical data

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Air conditioning system with refrigerant R134a - Edition 10.2014

– Remove defective part, purge with compressed air and collect

escaping refrigerant oil.

– A quantity of fresh refrigerant oil equal to the quantity of re‐

3

frigerant oil that has been blown out (plus 20 cm for the

3

evaporator, plus 10 cm for the condenser, refrigerant pipes

and refrigerant hoses) should be poured into the new compo‐

nent.

– Renew restrictor. Depending on vehicle

– Assemble refrigerant circuit, evacuate and charge.

11.2

Renewing air conditioner compressor

Note

On vehicles equipped with an electrical air conditioner compres‐

sor, de-energise the high-voltage system before removing the air

conditioner compressor. ⇒ Electric drive; Rep. gr. 93 ; Electric

drive; De-energising high-voltage system

11.2.1

Without needing to purge refrigerant cir‐

cuit of contaminants (cleaning), e.g. in

cases of external damage after an acci‐

dent

– Drain refrigerant circuit.

– Remove air conditioner compressor.

Note

If a different air conditioner compressor with other refrigerant oil

is fitted, purge the refrigerant circuit with R134a refrigerant

lk

⇒ page 67 .

Electrical air conditioner compressor:

If an electrical air conditioner compressor is renewed without hav‐

ing a mechanical fault (e.g. defective printed circuit board), the

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

11. Renewing components

161

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Air conditioning system with refrigerant R134a - Edition 10.2014

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

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

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.

lk

Mechanical air conditioner compressor:

– Remove oil drain screw from air conditioner compressor.

– To speed up the draining of the refrigerant oil, rotate the shaft

of the air conditioner compressor using the magnetic clutch

poly V-belt pulley. Not applicable for electrical air conditioner

compressor.

– 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

oils .

– Remove oil drain screw from genuine air conditioner com‐

pressor, pour out refrigerant oil and replace it with only the

quantity of fresh refrigerant oil equal to the amount of refrig‐

erant oil poured out of the defective air conditioner compres‐

sor.

Note

3

♦

If for instance 70 cm refrigerant oil was poured out of the de‐

3

fective air conditioner compressor, and 220 cm oil was pour‐

ed out of the genuine air conditioner compressor (a small

quantity of refrigerant oil remains in the air conditioner com‐

3

pressor), Pour 70 cm refrigerant oil into the genuine air con‐

ditioner compressor (the refrigerant oil previously poured out

of the genuine air conditioner compressor part may be used).

♦ Different air conditioner compressors require different types

and quantities of refrigerant oils ⇒ Rep. gr. 87 .

3

♦

If a large quantity of refrigerant oil (more than about 80 cm )

was poured from the defective air conditioner compressor, the

remaining refrigerant oil can also be poured into the evapora‐

tor or the reservoir or receiver ⇒ Rep. gr. 87 .

– Renew restrictor. Depending on vehicle

– Assemble refrigerant circuit, evacuate and charge.

162

Rep. gr.00 - Technical data

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Air conditioning system with refrigerant R134a - Edition 10.2014

11.2.2

Leaks or internal damage (e.g. noises or

lack of power)

– Drain refrigerant circuit.

– Remove air conditioner compressor.

Note

lk

♦ In the event of internal damage (to air conditioner compres‐

sor), purge with R134a refrigerant ⇒ page 67 .

♦ If a different air conditioner compressor with other refrigerant

oil is fitted, purge the refrigerant circuit with R134a refrigerant

⇒ page 67 .

– Renew receiver / dryer cartridge and expansion valve or res‐

ervoir and restrictor. Only if there was no more refrigerant in

the circuit.

– If leaking, examine the expansion valve for dirt or corrosion;

renew if necessary.

– Assemble refrigerant circuit, evacuate and charge.

11.3

Renewing receiver or reservoir, and re‐

strictor

11.3.1

After purging refrigerant circuit of con‐

taminants, e.g. due to moisture intrusion

(because refrigerant circuit has stood

open for a length of time) or due to dirt

The reservoir or receiver or cartridge of the dryer bag need not

be renewed under the following circumstances:

•

After an accident in which there was no damage to the reser‐

voir or receiver.

Repairs are performed quickly (no more delay than during a

normal repair time) and there was no moisture intrusion. The

vehicle is no more than 5 years old.

The reservoir or receiver or dryer cartridge should be renewed

under the following circumstances:

•

The refrigerant circuit was opened and the vehicle is more than

5 years old.

The refrigerant circuit has been opened for in indeterminate

period (seepage leak).

Repairs take longer than a normal repair time and there has

been moisture intrusion.

Always renew collector/reservoir or dryer cartridge after blow‐

ing through with compressed air or purging with refrigerant

R134a. Keep genuine parts sealed for as long as possible to

keep the ingress of moisture as low as possible.

•

The air conditioner compressor seizes.

The reservoir or receiver is damaged (e.g. in an accident).

– Drain refrigerant circuit.

– Remove air conditioner compressor.

11. Renewing components

163

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Air conditioning system with refrigerant R134a - Edition 10.2014

– Rectify cause of fault.

– Examine the expansion valve for dirt or corrosion; renew if

necessary.

– Remove oil drain screw from air conditioner compressor.

– To speed up the draining of the refrigerant oil, rotate the shaft

of the air conditioner compressor using the magnetic clutch

poly V-belt pulley.

– 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

oils .

– Then fill the air conditioner compressor with a quantity of new

refrigerant oil equal to the quantity in a genuine air conditioner

compressor ⇒ Rep. gr. 87 .

Note

♦ Types and quantities of refrigerant oils which should be used

for different air conditioner compressors ⇒ Rep. gr. 87 .

♦ To ensure proper lubrication of the air conditioner compressor

when it runs for the first time, the air conditioner compressor

3

must be filled with at least 80 cm of refrigerant oil; the re‐

mainder can be poured into the new reservoir or receiver ⇒

Rep. gr. 87 .

♦ If dirt enters the air conditioner compressor whilst the refrig‐

erant circuit is open (e.g. after an accident), the air conditioner

compressor should be renewed.

– Renew receiver or reservoir and restrictor.

– Assemble refrigerant circuit, evacuate and charge.

11.3.2

Without needing to purge refrigerant cir‐

cuit of contaminants (e.g. damage in an

accident); no refrigerant has escaped

and no moisture or dirt has entered re‐

frigerant circuit

– Drain refrigerant circuit.

– Renew restrictor. Depending on vehicle

– Remove receiver or reservoir.

– Clean any dirt out of receiver or reservoir.

– Weigh receiver or reservoir that was removed.

Note

♦ Fill enough refrigerant oil into the new reservoir or collector so

that it has the same weight as the container which was re‐

moved.

♦ Install new receiver or reservoir.

– Assemble refrigerant circuit, evacuate and charge.

164

Rep. gr.00 - Technical data

Renewingcomponents for Your Volkswagen LT Van Second Generation (1996-2006)

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