Get Renewingcomponents -> 11.2 Renewing air conditioner compressor 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

– Remove defective part, purge with compressed air and collect

escaping refrigerant oil.

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

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

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

⇒ 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

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

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‐

tioner compressor remains in the new one (plus 10 cm ). If, for

example, the new original air conditioner compressor is filled with

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.

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

♦

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

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‐

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 .

♦

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

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

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

♦ 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

Renewingcomponents -> 11.2 Renewing air conditioner compressor for Your Volkswagen LT Van Second Generation (1996-2006)

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