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

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Air conditioning system with refrigerant R134a - Edition 10.2014  
3
Statutory texts and instructions  
3.1  
Statutes and regulations  
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Note  
The laws and regulations listed below are valid in the Federal  
Republic of Germany. Other or additional laws and regulations  
may apply in other countries.  
Sources in other countries may be obtained from the respon‐  
sible authorities.  
The effects concerning the changing climate can be seen world-  
wide. The protection of the climate is therefore one of the most  
important tasks for the human race. This task is a massive chal‐  
lenge for all concerned.  
The so called Kyoto Protocol defines, amongst other items, world-  
wide targets to protect the climate. This protocol defines apart  
from the reduction targets for carbon dioxide, the reduction tar‐  
gets for fluoride containing greenhouse gases e.g. for refrigerant  
R134a due to the high greenhouse potential.  
Within Europe a large number of respective statutes exist for the  
motor industry. Nationally (Federal Republic of Germany) for ex‐  
ample in addition to European legislation, from the 1st of August  
2008 the climate protective regulation concerning chemicals  
comes into force.  
♦ Regulation (EU) No. 1005/2009  
♦ Regulation (EU) No. 2037/2000  
♦ Regulation (EU) No. 842/2006  
♦ Regulation (EU) No. 706/2007  
♦ Regulation (EU) No. 307/2008  
♦ Guideline 2006/40/EU  
♦ Climate protective regulation concerning chemicals; closed  
substance cycle waste management and ensuring environ‐  
mentally compatible waste disposal (only Germany)  
Maintenance and repairs to refrigerant circuits for air conditioning  
systems  
All personnel performing maintenance and repairs on air condi‐  
tioning systems for motorized vehicles must have attended the  
respective training programme and have the appropriate knowl‐  
edge (certified). Other legislation may apply outside the European  
Union.  
In general the following applies:  
Operation, maintenance, decommissioning, duty to accept re‐  
turned material  
♦ It is prohibited to allow the release into the atmosphere of ma‐  
terials contained in products containing refrigerants during the  
operation, maintenance or removal from service of such prod‐  
ucts.  
♦ The quantities used during operation and maintenance work  
should be documented (see Refrigerant Logbook, ⇒ Volks‐  
wagen InfoNet, Service handbook; Environmental protection;  
Environmental protection in the dealership and in the work‐  
shop; Emission protection; Air contaminating substances, re‐  
3. Statutory texts and instructions  
39  
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...  
Air conditioning system with refrigerant R134a - Edition 10.2014  
frigerant for vehicle air conditioning systems ) so that a proof  
of use document is available for presentation to the responsi‐  
ble authorities upon request. A record sheet need no longer  
be kept within the EU due to respective European parliament  
legislation from 2005. Other legislation may apply in countries  
not belonging to the EU.  
♦ Companies which sell materials and preparations listed in the  
above mentioned legislation have the duty of accept returned  
materials and preparations after they have been used, or to  
ensure that a specified third party will accept them.  
♦ Maintenance work and decommissioning of products that con‐  
tain refrigerant referred to in the above mentioned legislation  
as well as the acceptance of returned substances and prepa‐  
rations referred to in this legislation may only be carried out by  
persons who have the necessary specialist knowledge and  
technical equipment.  
Offences and breaches of the regulations  
♦ A person is in breach of the regulations and laws referred to if  
that person performs acts of wilful misconduct or negligence  
when operating, performing maintenance work on or decom‐  
missioning products that contain the refrigerants referred to,  
contrary to the norms of technical practice, allows the sub‐  
stances contained in them to escape into the atmosphere or  
wilfully or negligently breaches the applicable regulations and  
laws mentioned above.  
Make sure to observe the corresponding technical rules (e.g.  
TRGS 400, TRGS 402, TRGS 407, TRGS 510, TRGS 725, TRBS  
3145) when handling compressed gases and, in particular, when  
filling compressed gases from one compressed gas container into  
another one.  
Note  
The following paragraphs are only extracts from the Technical  
Rules for Hazardous Substances (TRGS) (relevant for automo‐  
lk  
bile manufacturers and workshops).  
♦ TRGS 400 (Risk assessment for activities involving hazardous  
substances).  
♦ TRGS 402 (Identification and assessment of the risks from  
activities involving hazardous substances: inhalation expo‐  
sure).  
♦ TRGS 407 (Risk assessment for activities involving gaseous  
substances).  
♦ TRGS 510 (Storage of hazardous substances in non-station‐  
ary containers).  
♦ TRBS 3145/TRGS 725 (Non-stationary compressed gas con‐  
tainers – charging, storage, in-house transportation, empty‐  
ing).  
40  
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  
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The Technical Rules for Compressed Gases (TRG), the Tech‐  
nical Rules for Hazardous Substances (TRGS) and the Tech‐  
nical Rules for Operational Safety (TRBS) reflect the state of  
technology, occupational safety and health, occupational hy‐  
giene as well as other definite knowledge relating to provision  
and use of work equipment, operation of facilities requiring  
supervision and activities involving hazardous substances.  
The technical rules stated here are valid in Germany and do  
not necessarily reflect the rules and regulations valid in other  
countries.  
Make sure to observe the corresponding technical rules (e.g.  
TRGS 400, TRGS 402, TRGS 407, TRGS 510, TRGS 725, TRBS  
3145) when handling compressed gases and, in particular, when  
filling compressed gases from one compressed gas container into  
another one.  
♦ Filling stations – general provisions.  
♦ Terms and definitions.  
♦ Filling stations – set-up and operation.  
Filling stations  
♦ This does not apply to vehicle manufacturers and workshops.  
♦ Filling stations are systems for charging non-stationary com‐  
pressed gas containers. A filling station comprises its corre‐  
sponding premises and equipment.  
♦ Charging systems that require authorisation are charging sys‐  
tems which are filled with compressed gases in mobile com‐  
pressed gas containers for transfer to other containers.  
♦ Filling stations that do not require authorisation are filling sta‐  
tions in which compressed gases are filled into non-stationary  
compressed gas containers for exclusive use within a compa‐  
ny.  
Employees and their instruction  
Employees are to be instructed in the following points before be‐  
ginning work as well as at regular, appropriate intervals, but at  
least annually:  
The particular hazards arising when handling compressed  
gases;  
The safety regulations, particularly the existing Technical  
Rules for Hazardous Substances (TRGS) and the Technical  
Rules for Operational Safety (TRBS);  
The actions to be taken in the event of defects, damage or  
accidents;  
The handing of fire extinguishers and protective equipment;  
The operation and maintenance of filling stations, with partic‐  
ular reference to the user's manual.  
Filling stations may be operated and maintained only by persons  
who  
are at least 18 years of age;  
possess the required technical knowledge;  
can be expected to fulfil their duties reliably.  
3. Statutory texts and instructions  
41  
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Air conditioning system with refrigerant R134a - Edition 10.2014  
Supervised work may be done by persons who do not fulfil the  
requirements according to item 2.1, figures 1 and 2.  
Charging pressure tanks (for tanks from other countries, other  
technical rules that are not mentioned here may apply).  
♦ A compressed gas container may be charged only with the  
compressed gas that is listed on its label, and only up to the  
quantity indicated on the container in terms of pressure, weight  
and volume (see Regulations for Pressure Tanks).  
♦ A container that can be used for different types of compressed  
gas must have a label on it listing the compressed gases with  
which it may be charged. If the compressed gas concerned  
has a tc ≥ -10°C (tc = critical temperature), the max. permis‐  
sible charging weight in accordance with TRGS must also be  
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indicated on the container before it is connected for charging.  
♦ Compressed gas containers for which the max. permissible  
charge overpressure at 15°C is given in bar must be charged  
by pressure gauge (manometer). If during charging the tem‐  
perature differs from 15°C, the pressure corresponding to the  
different temperature should be determined by the charging  
equipment; it must be ensured that the permissible positive  
pressure for charging at 15°C in the compressed gas container  
is not exceeded. To determine possible overcharging, the  
charged containers must be checked through random pres‐  
sure tests.  
Compressed gas containers on which the maximum permis‐  
sible charging quantity is indicated by the net weight (charged  
weight, permissible weight of the contents) in kilograms must  
be charged according to weight (gravimetrically). The contain‐  
ers must be weighed during charging and, to determine pos‐  
sible overcharging subsequently subjected to a weight check  
on a special scale. Scales for control weighing must be cali‐  
brated.  
♦ Under particular conditions, gases with tc ≥ +70°C from com‐  
pressed gas containers with a capacity of no more than 150 l  
may be charged into a compressed gas container with a ca‐  
pacity of no more than 1000 cc. The conditions of the TRGS  
apply to charging mechanic's bottles with liquid gas.  
♦ For vehicle containers, different TRGS apply:  
– For gases with tc ≥ +70°C.  
– For technical gas mixtures with tc ≥ +70°C.  
– Liquid, deep-cooled compressed gases in variance to those  
stated under item 4 may be charged by volume (volumetrical‐  
ly), if the charging device and/or the container with equipment  
is equipped with devices for measuring or limiting the volume  
of the charge and (except vehicle containers as specified un‐  
der item 3) for measuring the temperature of the charge. When  
charging by volume it must be ensured that the permitted  
charge weight shown on the container is not exceeded. To  
determine possible overcharging, the charged containers are  
to be checked gravimetrically on a calibrated scale or – provi‐  
ded that the pressurised gases are not highly toxic – volumet‐  
rically. Volumetric checking presupposes that the appropriate  
equipment is in place; charging and checking equipment must  
be independent of each other.  
♦ The charge and check measurements must not be performed  
by the same person. Check measurements must be per‐  
formed immediately upon conclusion of the charging process.  
Overcharged containers must be discharged immediately to  
the permissible charge quantity and in a manner without haz‐  
ard. Following this, the quantity of compressed gas charged  
must be determined once again.  
42  
Rep. gr.00 - Technical data  
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...  
Air conditioning system with refrigerant R134a - Edition 10.2014  
♦ Some regulations of the TRGS 407 do not (fully) apply to con‐  
tainers for liquid, deep-cooled compressed gases which are  
neither flammable nor toxic; regulations for traffic law remain  
unaffected.  
♦ When compressed gas containers are to be charged with  
gases in the liquid state at a charging temperature of ≤ -20°C,  
the compressed gas container must not be released from the  
charging system for transportation until the container wall has  
achieved a temperature ≥ +20°C (applies for vessel materials  
not tested for temperatures ≤ -20°C).  
Converting R12 refrigerant circuits to R134a refrigerant circuits  
and repairing them (retrofitting)  
Note  
Due to the environmental situation and the consequent legis‐  
lation, refrigerant R12 is currently neither in production nor  
available. Refrigerant R134a was developed as a replacement  
for R12.  
However, air conditioning systems developed and designed  
lk  
for refrigerant R12 cannot simply be charged with refrigerant  
R134a. To ensure trouble-free operation of the air conditioning  
system following a retrofit, various components of the refrig‐  
erant circuit must be replaced.  
An exact description of the procedure for conversion and in‐  
structions for repair of converted refrigerant circuits can be  
found in the ⇒ Repair manual for air conditioning systems with  
refrigerant R12 parts 2 and 3 . This workshop manual is only  
available as a hard copy.  
Maintaining records on refrigerant  
According to the environmental statistics law, a record concerning  
the use of refrigerants must be kept.  
Car manufacture and repair businesses must be prepared to fur‐  
nish information concerning use of refrigerants to the statistical  
office for the country in which the work is being performed. It is  
therefore recommended to keep records of the amounts of refrig‐  
erant handled during operation and maintenance (Refrigerant  
Logbook) ⇒ Volkswagen ServiceNet, Environmental Protection;  
Service handbook; Emission protection; Air contaminating sub‐  
stances, refrigerant for vehicle air conditioning systems ) which  
must be available for presentation to the responsible authorities  
upon request.  
Note  
A record sheet need no longer be kept within the EU due to re‐  
spective European parliament legislation from 2005. Other legis‐  
lation may apply in countries not belonging to the EU.  
3. Statutory texts and instructions  
43  
Amarok 2011 ➤ , Beetle 2012 ➤ , Bora 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , ...  
Air conditioning system with refrigerant R134a - Edition 10.2014  
3.2  
Recycling and refuse law  
Note  
The laws and regulations listed below are valid in the Federal  
Republic of Germany. Other or additional laws and regulations  
may apply in other countries.  
Sources in other countries may be obtained from the respon‐  
sible authorities.  
Statutes and regulations concerning the use and disposal of re‐  
frigerants and refrigerant machine oils are contained within the  
climate protective regulation concerning chemicals and closed  
substance cycle waste management and ensuring environmen‐  
tally compatible waste disposal (only for Germany, in other coun‐  
tries other statutes and regulations may apply).  
3.2.1  
Disposal of refrigerant and refrigerant  
machine oil  
Refrigerant  
Refrigerants intended for disposal are to be charged into marked  
recycling containers under the observation of permissible charge  
quantities. Observe, for example in the Federal Republic of Ger‐  
many, the climate protective regulation concerning chemicals;  
closed substance cycle waste management and ensuring envi‐  
ronmentally compatible waste disposal (in other countries other  
statutes and regulations may apply)  
Refrigerant machine oil  
Disposing of used oil: Volkswagen InfoNet; Operation; Manuals  
and dealership documentation; Service handbook; 15. Environ‐  
mental Protection; Follow link “Environmental protection in the  
dealership and in the workshop” in "General notes"; 4. Waste dis‐  
posal; 6. Disposal channels; g. Disposal of used oil; Refrigerant  
oils  
lk  
Used refrigerant machine oils from systems with halogenated hy‐  
drocarbons (at least one hydrogen atom has been replaced by  
e.g the halogens flourine, chlorine, bromine or iodine) must be  
disposed of as waste requiring particular care. It is impermissible  
to mix such oils with other oils or materials. Proper storage and  
disposal must be performed according to guidelines in the country  
where the work is being performed. Observe, for example in the  
Federal Republic of Germany, the climate protective regulation  
concerning chemicals; closed substance cycle waste manage‐  
ment and ensuring environmentally compatible waste disposal (in  
other countries other statutes and regulations may apply)  
44  
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  
Reference sources for technical rules and safety at work / acci‐  
dent prevention for the Federal Republic of Germany  
Sources in other countries may be obtained from the responsible  
authorities  
3.3  
Converting R12 refrigerant circuits to  
R134a refrigerant circuits and repairing  
them (retrofitting)  
Note  
The laws and regulations listed below are valid in the Federal  
Republic of Germany. Other or additional laws and regulations  
may apply in other countries.  
Sources in other countries may be obtained from the respon‐  
sible authorities.  
Due to the environmental situation and the consequent legis‐  
lation, refrigerant R12 is currently neither in production nor  
available. Refrigerant R134a was developed as a replacement  
for R12.  
However, air conditioning systems developed and designed  
for refrigerant R12 cannot simply be charged with refrigerant  
R134a. To ensure trouble-free operation of the air conditioning  
system following a retrofit, various components of the refrig‐  
erant circuit must be replaced.  
An exact description of the procedure for conversion and in‐  
structions for repair of converted refrigerant circuits can be  
found in the ⇒ Repair manual for air conditioning systems with  
refrigerant R12 parts 2 and 3 . This workshop manual is only  
available as a hard copy.  
3.4  
Maintaining records on refrigerant  
Note  
The laws and regulations listed below are valid in the Federal  
Republic of Germany. Other or additional laws and regulations  
may apply in other countries.  
Sources in other countries may be obtained from the respon‐  
sible authorities.  
The quantities used during operation and maintenance work  
should be documented (see Refrigerant Logbook, ⇒ Volkswagen  
ServiceNet, Environmental Protection; Service handbook; Emis‐  
sion protection; Air contaminating substances, refrigerant for ve‐  
hicle air conditioning systems ) or proof of use document which  
must be available for presentation to the responsible authorities  
upon request. A record sheet need no longer be kept within the  
EU due to respective European parliament legislation from 2005.  
Other legislation may apply in countries not belonging to the EU.  
3. Statutory texts and instructions  
45  

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