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Air conditioning system with refrigerant R134a - Edition 10.2014

00 – Technical data

1

General notes on air conditioning

systems

(VRL007231; Edition 10.2014)

1.1

Introduction

This repair manual is intended to provide technicians and fitters

with the basic knowledge required for performing trained work on

these systems.

Note

♦ Successful completion of a training course such as AB160 or

ST160 Air conditioning systems including "technical informa‐

tion" is required.

♦ This repair manual is a part of the training material.

It should also be available to the responsible supervisory author‐

lk

ities upon request.

Caution

Non-authorised tools or materials (e.g. leak inhibitor additive)

may cause damage or adversely influence the system.

Only tools and materials approved by the manufacturer may

be used.

Use of non-approved tools or materials will render the warranty

void.

1.2

Additional information

♦ Technical Service Handbook with measures for rectifying lat‐

est malfunctions.

♦ Workshop manual for service work specific to model ⇒ Heat‐

ing, air conditioning; Rep. gr. 87 .

♦ ⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐

cations

♦ Self-study programme No. 208 is no longer up-to-date in some

sections. E.g. the statement “The receiver must be renewed

each time the refrigerant circuit is opened”. The following con‐

ditions apply ⇒ page 159

♦ Video programs for staff training.

♦ Catalogue of special tools / workshop testing.

♦ Service Organisation Volume 1 Additional equipment.

♦ Workshop manual for air conditioning system with R12 refrig‐

erant (for vehicles that were manufactured up to model year

1993). This workshop manual is only available as a hard copy.

1. General notes on air conditioning systems

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1.3

Basics of air conditioning

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1.3.1

Physical basics:

The four known physical states of water also apply to air condi‐

tioning refrigerants.

1 - Gas (invisible)

2 - Vapour

3 - Liquid

4 - Solid

When water is heated in a container (heat absorption), the rising

water vapour is visible. If the vapour is heated by further heat

absorption, the visible vapour becomes invisible gas. This proc‐

ess is reversible. If heat is extracted from gaseous water, it

changes first to vapour, then to water and finally to ice.

A - Heat absorption

B - Heat dissipation

1.3.2

Heat always flows from warmer to colder

material

Every material consists of a mass of moving molecules. The fast

moving molecules of a warmer material loose part of their energy

to slower molecules possessing less heat. This slows down the

molecules of the warmer material and accelerates those with less

heat. This continues until the molecules in both materials are

moving at the same speed. They have the same temperature, and

no further exchange of heat occurs.

1.3.3

Pressure and boiling point

The boiling points given in the table below are always based on

an atmospheric pressure of 1 bar. If the pressure on a liquid is

changed, its boiling point changes also.

It is well known that, for example, the lower the pressure, the lower

the temperature at which water boils.

The vapour pressure curves for water and for refrigerant R134a

show that at constant pressure and falling temperature the vapour

becomes liquid (in the condenser), and that when pressure drops,

the refrigerant changes from liquid into the vapour state (evapo‐

rator).

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Vapour pressure curve for water

A - Liquid

B - Gaseous

C - Vapour pressure curve for water

1 - Pressure on the liquid in bar (absolute)

2 - Temperature in °C

Vapour pressure curve for refrigerant R134a

A - Liquid

B - Gaseous

D - Vapour pressure curve for refrigerant R134a

1 - Pressure on the liquid in bar (absolute)

2 - Temperature in °C

1.4

Vapour pressure table for refrigerant

R134a

The vapour pressure table for each refrigerant is published in the

literature for refrigeration engineers. This table shows the vapour

pressure exerted on the liquid column in the container for a given

temperature of the container.

Since a characteristic vapour pressure table is known for every

refrigerant, one can determine what refrigerant is present by

measuring pressure and temperature.

Note

Absolute pressure means that 0 bar corresponds to an absolute

vacuum. The normal ambient pressure (positive pressure) corre‐

sponds to 1 bar absolute pressure. On most pressure gauges, a

reading of 0 bar corresponds to an absolute pressure of one bar

(which is confirmed by the existence of a -1 bar marking beneath

the 0 scale marking).

Temperature in °C

Pressure in bar (positive pres‐

sure) R134a

-45

-40

-35

-30

-25

-20

-15

-10

-5

-0.61

-0.49

-0.34

-0.16

0.06

0.32

0.63

1.00

1.43

1.92

0

1. General notes on air conditioning systems

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Temperature in °C

Pressure in bar (positive pres‐

sure) R134a

5

2.49

3.13

10

15

20

25

30

35

40

45

50

55

60

65

70

75

80

85

90

3.90

4.70

5.63

6.70

7.83

9.10

10.54

12.11

13.83

15.72

17.79

20.05

22.52

25.21

28.14

31.34

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1.5

Refrigerant R134a

Air conditioners in vehicles use the evaporation and condensation

process. The system contains a liquid with a low boiling point,

called the refrigerant.

The refrigerant used is tetrafluoroethane R134a, which boils at

-26.5°C with vapour pressure of 1 bar.

1.5.1

Physical data of refrigerant R134a

Chemical formula

Chemical designation

Boiling point at 1 bar

Freezing point

CH2F–CF3 or CF3–CH2F

Tetrafluoroethane

-26.5℃

-101.6℃

Critical temperature

Critical pressure

100.6℃

40.56 bar (technical) pressure

equates to 39.5 bar (standard)

pressure

1.5.2

Critical point

Critical point (critical temperature and critical pressure) means the

point above which there is no longer a surface of separation be‐

tween liquid and gas.

Above its critical point, a substance is always gaseous.

At temperatures below the critical point, all types of refrigerant

contained within a pressure tank exhibit a liquid phase and a gas

phase, so that there is a gas cushion above the liquid.

As long as there is gas in the pressure vessel alongside the liquid,

the pressure depends directly on the ambient temperature

⇒ page 3 .

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Note

Different types of refrigerants must not be mixed with each other.

Only refrigerants specified for the respective air conditioning sys‐

tem may be used.

1.5.3

Environmental aspects of refrigerant

R134a

lk

♦ R134a is a fluorocarbon and contains no chlorine.

♦ R134a has a shorter atmospheric persistence than refrigerant

R12.

♦ R134a does not damage the ozone layer, the potential to re‐

duce the amount of ozone is zero.

♦ The Global Warming Potential (GWP) of R134a lies by ap‐

prox. 1430 (the GWP for carbon dioxide lies by 1).

♦ The contribution of R134a to the greenhouse effect is less by

a factor of 10 than that of refrigerant R12.

1.6

Characteristics of refrigerant R134a

1.6.1

Trade names and designations

Refrigerant R134a is currently available under the following trade

designations:

♦ H-FKW 134a

♦ SUVA 134a

♦ KLEA 134a

Note

♦ Other trade designations may be used in other countries.

♦ Among the large selection of various refrigerants, only this one

may be used for vehicles. The designations Frigen or Freon

are trade names. They apply also to refrigerants which must

not be used in vehicles.

1.6.2

Colour

Like water, the refrigerant is colourless both in the vapour state

and the liquid state. Gases are invisible. Only the boundary layer

between gas and liquid is visible. (Fluid level in indicator tube of

charging cylinder for bubbles in sight glass.) Liquid refrigerant

R134a may appear coloured (milky) in a sight glass. This cloudi‐

ness is caused by partially dissolved refrigerant oil and does not

indicate a fault.

1.6.3

Vapour pressure

In an enclosed container that is not completely full, refrigerant

evaporates as vapour at the surface in a quantity sufficient to form

an equilibrium between vapour and liquid. This equilibrium de‐

velops under pressure and is often called vapour pressure. The

vapour pressure is temperature-dependant ⇒ page 3 .

1. General notes on air conditioning systems

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1.6.4

Physical properties of R134a

Because the vapour pressure curves of R134a and other refrig‐

erants are in part very similar, unique identification on the basis

of pressure alone is not possible.

The air conditioner compressor used for R134a is lubricated with

special synthetic refrigerator oils, such as PAG oils (polyalkylene

glycol oils).

1.6.5

Effects on metal

In its pure state, refrigerant R134a is chemically stable and does

not attack iron or aluminium.

However, impurities such as chlorine compounds in the refriger‐

ant do attack certain metals and plastics. This can lead to block‐

ages, leaks and deposits on the air conditioner compressor

piston.

1.6.6

Critical temperature and critical pres‐

sure

Up to a gas pressure of 39.5 bar positive pressure (corresponding

to a temperature of 101°C) the refrigerant R134a remains chem‐

ically stable; however, above this temperature the refrigerant

decomposes (see Combustibility).

1.6.7

Water content

Only very small amounts of water are soluble in liquid refrigerant.

On the other hand, refrigerant vapour and water vapour mix in

any proportion.

lk

Any water present in the refrigerant circuit will be carried along as

droplets. The dryer, dryer bag or dryer cartridge in the receiver or

reservoir are capable of holding approx. 7 grams of water before

they are full and cannot absorb any more water. If there is further

water in the circuit, it will flow to the expansion valve jet or to the

restrictor and becomes ice.

The air conditioning system will stop cooling.

Water destroys the air conditioner because at high pressures and

temperatures it combines with other impurities to form acids.

1.6.8

Combustibility

Refrigerant is non-flammable. On the contrary, it has a fire-inhib‐

iting or fire-extinguishing effect. Refrigerant decomposes when

exposed to flames or incandescent surfaces. UV light can also

decompose refrigerants (UV is emitted by electric arc welding).

Products of this decomposition are poisonous and must not be

inhaled. However, these chemicals irritate the mucous mem‐

branes, giving adequate warning of their presence.

1.6.9

Charge factor

There must be space both for liquid and vapour in a container. As

the temperature rises, the liquid expands. The space occupied by

the vapour becomes smaller. Eventually, there will only be liquid

in the container. After that time, even a small increase in temper‐

ature will result in a very large increase in pressure, since the

liquid is seeking to expand further but there is no space for it to

do so. The resulting forces are sufficient to burst the container.

To prevent containers from being overcharged, regulations gov‐

erning the storage of compressed gases specify how many kilo‐

grams may be charged into a container for every litre of container

volume. This charge factor multiplied by the internal volume gives

the permissible charge quantity. The charge factor for the refrig‐

erants used in cars is 1.15 kg/l.

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1.6.10

Detecting leaks

External damage can cause leaks in the refrigerant circuit. Be‐

cause a small leak will involve only small quantities of refrigerant,

leaks should be checked for using an electronic leak detector or

by introducing a leak detection additive to the refrigerant circuit.

Electronic leak detectors can detect leakage rates of less than 5

grams loss of refrigerant per year. The leak detector should be

specific to the composition of the particular refrigerant in use. For

example, a leak detector for R12 refrigerant is not appropriate for

R134a refrigerant because R134a refrigerant has no chlorine

atoms to which the lead detector responds.)

1.7

Refrigerant machine oil

Refrigerant machine oil is miscible (approx. 20%–40% depending

on the type of air conditioner compressor and the quantity of re‐

frigerant) in the refrigerant. It circulates continuously in the circuit

and lubricates the moving parts.

Special synthetic refrigerant machine oils such as polyalkylene

glycol (PAG) oil are used in conjunction with R134a air condition‐

ing systems. This is necessary because ordinary mineral oils are

immiscible in R134a. In addition the materials of the R134a air

conditioning system could be attacked if the mixture circulated

within the refrigerant circuit under pressure and at high tempera‐

tures, or the lubricant film in the air conditioner compressor broke

down. The use of unapproved oils can lead to the failure of the air

conditioning system, so only approved oils must be used.

lk

⇒ Parts catalogue

Type of oil for R134a in cars: PAG

1. General notes on air conditioning systems

7

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Note

♦ Do not store refrigerant machine oils open to the atmosphere

since they are very hygroscopic (they readily absorb water).

♦ Always keep oil containers tightly sealed.

♦ Do not reuse used refrigerant machine oil.

♦ Disposing of used oil: Volkswagen InfoNet; Operation; Man‐

uals and dealership documentation; Service handbook;

15. Environmental Protection; Follow link “Environmental pro‐

tection in the dealership and in the workshop” in "General

notes"; 4. Waste disposal; 6. Disposal channels; g. Disposal

of used oil; Refrigerant oils

♦ Used refrigerant machine oils from systems with halogenated

hydrocarbons (at least one hydrogen atom has been replaced

by e.g the halogens fluorine, chlorine, bromine or iodine) must

be disposed of as waste requiring particular care. It is imper‐

missible to mix such oils with other oils or materials. Proper

storage and disposal must be performed according to guide‐

lines in the country where the work is being performed. Ob‐

serve, for example in the Federal Republic of Germany, the

climate protective regulation concerning chemicals; closed

substance cycle waste management and ensuring environ‐

mentally compatible waste disposal (in other countries other

statutes and regulations may apply)

♦ Reference sources for technical rules and safety at work / ac‐

cident prevention for the Federal Republic of Germany

♦ Sources in other countries may be obtained from the respon‐

sible authorities

♦ Ester-based oils are suitable only for larger systems (not for

air conditioning systems in cars).

1.7.1

Properties of refrigerant oils

The most important properties are high solubility in refrigerants,

good lubrication characteristics, freedom from acid and very low

water content. For this reason, only certain oils may be used. A

list of approved refrigerant oils and quantities can be found in the

vehicle-specific workshop manuals in ⇒ Rep. gr. 00 or ⇒ Rep.

gr. 87 .

The PAG oils suitable for refrigerant R134a are strongly hygro‐

scopic and are immiscible with other oils. Therefore, opened

containers should be closed again immediately to protect them

from moisture. Refrigerant oils age under the influence of mois‐

ture and acids; they become dark, viscous and aggressive to‐

wards metals.

Note

♦ For refrigerant circuits with refrigerant R134a, use only the oil

approved for the air conditioner compressor. See ⇒ Rep. gr.

00 or ⇒ Rep. gr. 87 in the repair manual for the specific ve‐

hicle.

♦ Disposing of used oil: Volkswagen InfoNet; Operation; Man‐

uals and dealership documentation; Service handbook;

15. Environmental Protection; Follow link “Environmental pro‐

tection in the dealership and in the workshop” in "General

notes"; 4. Waste disposal; 6. Disposal channels; g. Disposal

of used oil; Refrigerant oils

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1.8

Comfort

A basic requirement for concentrated and safe driving is the feel‐

ing of comfort in the passenger compartment. Especially when it

is hot and humid, comfort can be attained only through the use of

air conditioning. Of course, open windows, an open sunroof or

increased air ventilation can contribute to comfort, but they all

have certain disadvantages within the vehicle interior, such as

additional noise, draughts, exhaust gases, unfiltered entry of pol‐

len (unpleasant for allergy sufferers).

A well regulated air conditioning system in conjunction with a well

thought-out heating and ventilation system can create a feeling

of well-being and comfort by regulating the interior temperature,

humidity and rate of air change, regardless of the external con‐

ditions. This must be available whether the vehicle is moving or

not.

Other important advantages of air conditioning are

♦ The cleansing of the air directed into the passenger compart‐

ment. (Dust and pollen, for example, are washed out by the

moist fins of the evaporator and carried off with the conden‐

sation water.)

♦ Temperatures in a mid-range car (for example, after a short

lk

period of driving, ambient temperature 30°C in the shade and

the vehicle in direct sunlight).

With air conditioning Without air condi‐

system

23℃

24℃

tioning system

42℃

Head region

Chest region

Footwell

40℃

35℃

30℃

1.8.1

Environmental aspects

Since about 1992, the air conditioning systems of newly manu‐

factured cars have been successively changed to refrigerant

R134a. This refrigerant contains no chlorine and thus does not

damage the ozone layer.

Up until about 1992, air conditioning systems were charged with

refrigerant R12. Due to its chlorine atoms, this CFC has a high

potential for destroying ozone and, in addition, a potential for in‐

creasing the greenhouse effect.

There are programs for exchanging old air conditioning systems

containing the ozone-damaging refrigerant R12.

⇒ Repair manual for air conditioning systems with refrigerant

R12 . This workshop manual is only available as a hard copy.

To protect the environment, no refrigerant should be released into

the atmosphere ⇒ page 39 (statutory texts and instructions).

1.9

How air conditioning works

The temperature in the passenger compartment depends on the

amount of heat radiated through the windows and conducted by

the metal parts of the body. In order to maintain comfortable tem‐

peratures for the occupants on very warm days, part of the

available heat must be pumped away.

Since heat spreads towards cooler bodies, a unit that can create

low temperatures is fitted in the vehicle interior. Refrigerant is

constantly being evaporated in it. The latent heat of evaporation

is taken from the air passing through the evaporator.

The refrigerant carries the heat with it as it is pumped away by the

air conditioner compressor. The work performed by the air con‐

1. General notes on air conditioning systems

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ditioner compressor on the refrigerant increases its heat content

and its temperature. Its temperature is now considerably higher

than that of the ambient air.

The hot refrigerant flows with its heat content to the condenser.

There the refrigerant looses its heat through the condenser to the

surrounding air due to the temperature gradient between the re‐

frigerant and the surrounding air.

Thus, the refrigerant is a means of heat transport. Because it will

be needed again, it returns to the evaporator.

All air conditioning systems basically depend on the circulation of

refrigerant. However, there are differences in the construction of

the system.

1.10

General safety

♦ In accordance with VBG 20, the Federation of Employers Li‐

ability Insurance Associations.

♦ 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.

1.10.1

Product characteristics

Refrigerants used in car air conditioning systems belong to the

new generation of refrigerants, the chlorine-free, partially-fluori‐

dated hydrocarbons (H-CFC, R134a).

lk

In regard to their physical behaviour, they are refrigerants which

can be liquefied under pressure. They are subject to Regulations

for Pressure Tanks and may be charged only into approved and

identified pressurised gas containers.

Specific conditions which apply for safe and proper use must be

maintained.

1.10.2

Handling refrigerants

WARNING

Danger of freezing injuries.

The refrigerant can emerge as liquid or as vapour.

Do not open containers in which this refrigerant is present.

If refrigerant containers are opened, the contents may escape in

liquid or vapour form. The higher the pressure in the container,

the more energetic the emergence will be.

How high the pressure is depends on two factors:

•

What type of refrigerant is in the container. “This is because

the lower the boiling point, the higher the pressure.”

•

How high the temperature is. “This is because the higher the

temperature, the higher the pressure.”

1.10.3

Wear protective glasses

Put on protective glasses. This will prevent the refrigerant enter‐

ing the eyes, which in certain circumstances can cause severe

injury due to frostbite.

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1.10.4

Wear protective gloves and apron

Refrigerants dissolve fats and oils very well. Therefore, when they

come in contact with the skin, they take away the protective layer

of fat. Skin from which the natural ^lo^kil and fat have been removed

is vulnerable to cold and germs.

1.10.5

Do not allow liquid refrigerant to come in

contact with the skin

The refrigerant will draw its latent heat of evaporation from its

surroundings. That can be your skin. This can result in very low

temperatures. The result is local frostbite (boiling point of R134a

is -26.5°C at normal atmospheric pressure).

1.10.6

Do not breath in refrigerant vapour

Note

In high concentrations, emerging refrigerant vapours can mix with

the air and displace the oxygen necessary for breathing.

1.10.7

Absolutely NO SMOKING

Refrigerant can decompose in a burning cigarette. The resulting

substances are poisonous and must not be breathed in.

1.10.8

Welding and soldering on refrigeration

systems

Before welding and brazing on vehicles (in the vicinity of the air

conditioning system components), extract the refrigerant and

then purge the system by blowing through with compressed air

and using nitrogen.

The products of decomposition of refrigerants under heat are not

only poisonous but are strongly corrosive, so that pipework and

system parts could be attacked. This refers primarily to hydrogen

fluoride.

1.10.9

Pungent smell

A pungent odour indicates that the products of decomposition

mentioned above are already present. Breathing in these sub‐

stances must be avoided under all circumstances, or the bron‐

chial tubes, lungs and other organs could be injured.

1.10.10 First aid

•

In the event of contact with the eyes or mucous membranes,

wash immediately with copious running water and summon an

eye specialist.

•

In the event of contact with the skin, remove wetted clothing

and wash the affected skin with copious water.

If refrigerant vapours are breathed in high concentrations, take

the patient immediately into the fresh air. Summon a doctor. If

the patient has trouble breathing, administer oxygen. If the

patient's breathing is restricted or stops, bend the head at the

neck and commence resuscitation.

1.10.11 Handling pressure tanks

•

Secure vessels against falling over!

Secure standing cylinders against falling over and lying cylinders

from rolling away.

1. General notes on air conditioning systems

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Air conditioning system with refrigerant R134a - Edition 10.2014

•

Do not throw pressure vessels!

When falling, the containers may become severely deformed so

that they may be torn open. The refrigerant evaporates immedi‐

ately, releasing violent forces. Flying fragments of cylinders can

cause severe injuries.

Bottle valves can brake during improper transport. To protect cyl‐

inder valves, bottles may be transported only with protective

covers screwed on.

•

Do not place near radiators!

High temperatures can occur near radiators. Higher temperatures

however also mean higher pressures, which may exceed the rat‐

ed pressure of the vessel.

1.10.12 Do not heat above 50°C

To prevent danger, the Regulations for Pressure Tanks provide

that tanks shall not be heated to more than 50°C.

1.10.13 Do not apply uncontrolled heat

Do not heat with an open flame under any circumstance. The local

overheating that will result can change the structure of the con‐

tainer's materials, thereby reducing the safe maximum pressure

limit of the container. In addition, the danger arises that the re‐

frigerant decomposes due to localised overheating.

1.10.14 Seal empty containers

Empty refrigerant containers must in all cases be sealed so as to

prevent intrusion of moisture. Moisture causes steel containers to

rust. This weakens the walls of the containers. In addition, rust

particles which enter the refrigerant system from the container

cause malfunctions.

1.10.15 Safety instructions for using extraction

and charging equipment

•

Before connecting the charging system to the air conditioning

system, make sure that all existing shut-off valves are closed.

•

Before the charging equipment is decoupled from the air con‐

ditioning system, ensure that the process has finished. The

reason for this is to ensure that no refrigerant oil escapes into

the atmosphere.

•

After the cleaned refrigerant from the charging system has

been charged into an external pressurised gas cylinder, close

the hand shut-off valves on the bottle and the charging system.

•

Do not expose charging system to moisture or use it in a wet

environment.

Before performing service work and the charging system, dis‐

connect the current supply.

To reduce danger of fire, avoid using extension cords. If nev‐

ertheless it is necessary to use an extension cable, use an

2

extension cable with a cross-section of at least 2.5 mm .

•

In case of fire, remove external cylinder.

If entrained oil from the air conditioning system suction accu‐

mulator is trapped in the measuring beaker supplied, be sure

subsequently to pour the oil into a container that can be

sealed, since the oil contains a small amount of refrigerant.

Refrigerants must not be released into the environment.

•

When the air conditioner service station is switched off, it must

be secured against rolling away.

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1.11

Safety precautions for when working on

vehicles with air conditioning and when

handling refrigerant R134a

Air conditioning service station - VAS 6007A- (and further service

stations currently available)

⇒ Workshop equipment

WARNING

♦ It is recommended that a bottle containing water be kept

at hand for purging out the eyes.

♦ Should liquid refrigerant get into the eyes, thoroughly

purge the eyes with water for about 15 minutes. Then ad‐

minister eye drops and visit a doctor immediately even if

the eyes do not hurt.

♦ The doctor must be informed that the frostbite has been

caused by refrigerant R134a. If, in spite of these safety

measures, refrigerant comes into contact with other body

parts, these areas must also be immediately purge with

cold water for at least 15 minutes.

♦ Work on the air conditioning system refrigerant circuit in

well ventilated rooms only. Switch on exhaust gas fume

extractor (if there is one).

♦ Refrigerant must not be stored in low-lying rooms (e.g.

cellars) or their stairways or window shafts.

•

Do not weld, braze or soft-solder any parts of the charged air

conditioning system. This also applies to welding and solder‐

ing work on the vehicle when the danger exists that parts of

the air conditioning system may heat up. During painting op‐

erations, temperatures of objects in the drying oven or in its

pre-heating zone must not exceed 80°C.

Reason:

Heating causes great excess pressure to develop in the system,

which can cause the pressure release valve of the system to

open.

Precautions:

– Use the air conditioner service station to evacuate the refrig‐

erant circuit.

Note

Damaged or leaking components of the air conditioning system

must not be repaired by welding or soldering. They must always

be renewed.

Refrigerant containers (e.g. charging cylinders of air conditioner

service station) must never be subjected to excessive heat or ex‐

posed to direct sunlight.

Precautions:

– Never charge a container completely with liquid refrigerant.

Without sufficient expansion space (gas cushion), the con‐

tainer will burst should the temperature rise, with devastating

consequences ⇒ page 5 .

1. General notes on air conditioning systems

13

lk

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:

14

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.

lk

♦ 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

3

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

15

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.

16

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

2

General information on refrigerant

circuit

2.1

Refrigerant circuit components

Caution

Non-authorised tools or materials (e.g. leak inhibitor additive)

may cause damage or adversely influence the system.

Only tools and materials approved by the manufacturer may

be used.

Use of non-approved tools or materials will render the warranty

void.

•

All components of the refrigerant circuit that were submitted

for quality monitoring must always be sealed (use the original

sealing caps from the genuine part).

•

Renew damaged or leaky components of the refrigerant circuit

⇒ page 159 .

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

ceiver, evaporator and condenser) are charged with nitrogen

before shipment. This filling is being gradually discontinued.

Therefore, when the sealing plugs are unscrewed from the

genuine part little or no pressure equalisation is noticeable.

2.1.1

Distribution of the refrigerant circuit

components and their influence on the

high-pressure and l^lo^kw-pressure sides

On the high-pressure side, there are the condenser, the receiver

and the restrictor or expansion valve that acts as the separation

between the high-pressure fluid and low-pressure fluid sides.

High pressure is created because the restrictor or expansion

valve forms a restriction and holds back the refrigerant, leading

to increased pressure and temperature.

Excessive pressure results if the circuit is filled with too much re‐

frigerant or refrigerant oil, or the condenser is dirty, the radiator

fan is defective, there is a blockage in the system or there is

moisture in the refrigerant circuit (causing the restrictor or expan‐

sion valve to ice up).

On the low-pressure side, there are the evaporator, the reservoir,

the temperature sensor for the evaporator and the air conditioner

compressor that acts as the separation between the high-pres‐

sure and low-pressure gas sides.

A loss of pressure in the system can be due to loss of refrigerant,

restrictor or expansion valve failure (not creating a restriction),

defective air conditioner compressor or an iced-up evaporator.

2. General information on refrigerant circuit

17

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Air conditioning system with refrigerant R134a - Edition 10.2014

2.1.2

Air conditioning system compressor with

magnetic clutch:

The air conditioner compressor is driven by a V-belt from the en‐

gine.

An electromagnetic clutch is fitted to the air conditioner compres‐

sor. When the air conditioning system is switched on, it transmits

the mechanical drive between the V-belt pulley and the air con‐

ditioner compressor drive shaft.

A fusible link is incorporated in the air conditioner compressor V-

belt pulley. In the event of stiffness in the air conditioner com‐

pressor, it trips the electromagnetic clutch and protects the V-belt

drive from overload.

The air conditioner compressor draws refrigerant gas from the

evaporator, compresses it and sends it to the condenser.

Note

♦ The air conditioner compressor contains refrigerant oil, which

can be mixed with R134a refrigerant at any temperature.

♦ The maker's nameplate states the refrigerant for which the air

conditioner compressor is suitable. A valve regulates the pres‐

sure on the low-pressure side within the specified range (reg‐

ulation characteristic).

♦ So that the air conditioner compressor suffers no damage

when the refrigerant circuit is empty, the magnetic clutch is

disconnected and the regulating valve for the air conditioner

compressor - N280- is no longer activated (the air conditioner

compressor idles with the engine).

18

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

2.1.3

Air conditioner compressor without

magnetic clutch

The air conditioner compressor is driven by a V-belt from the en‐

gine.

A shear link is incorporated in the air conditioner compressor V-

belt pulley. In the event of stiffness in the air conditioner com‐

pressor, it shears off and protects the V-belt drive from overload.

The air conditioner compressor draws refrigerant gas from the

evaporator, compresses it and sends it to the condenser.

Note

♦ The air conditioner compressor contains refrigerant oil, which

is miscible with R134a refrigerant at all temperatures.

♦ The maker's nameplate states the refrigerant for which the air

conditioner compressor is suitable. A valve regulates the pres‐

sure on the low-pressure side within the specified range (reg‐

ulation characteristic).

♦ The regulating valve for this air conditioner compressor is ex‐

ternally activated.

lk

♦ The engine should be started only when the refrigerant circuit

has been fully assembled ⇒ page 14 .

♦ 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

3

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

pressor.

2. General information on refrigerant circuit

19

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

Air conditioning system with refrigerant R134a - Edition 10.2014

2.1.4

Air conditioner compressor without

magnetic clutch, with elastic drive cou‐

pling

The air conditioner compressor is driven directly by the power

steering vane pump.

There is an overload protection on the drive shaft of the air con‐

ditioner compressor, which shears in the event of the air condi‐

tioner compressor seizing, thus permitting the power steering

vane pump to remain operational.

lk

The air conditioner compressor draws refrigerant gas from the

evaporator, compresses it and sends it to the condenser.

Note

♦ The air conditioner compressor contains refrigerant oil, which

is miscible with R134a refrigerant at all temperatures.

♦ The maker's nameplate states the refrigerant for which the air

conditioner compressor is suitable. A valve regulates the pres‐

sure on the low-pressure side within the specified range (reg‐

ulation characteristic).

♦ The regulating valve for this air conditioner compressor is ex‐

ternally activated.

♦ The engine should be started only when the refrigerant circuit

has been fully assembled ⇒ page 14 .

♦ 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

3

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

pressor.

2.1.5

Electrical air conditioner compressor for

high-voltage system

WARNING

♦ High voltage on high-voltage system of hybrid vehicle!

Health risks for persons wearing medical devices!

♦ Following procedure also requires work on high-voltage

system. All work on vehicles with a high-voltage system

may only be done by trained electricians. Work must be

advised by a high-voltage technician.

♦ Observe the general warning instructions for work on the

high-voltage system ⇒ Electric drive, Repair group 93;

General warning instructions for work on the high-voltage

system.

♦ Now, ensure there is no voltage in high-voltage system ⇒

Electric drive, Repair group 93; Ensuring there is no volt‐

age in high-voltage system.

20

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

WARNING

The electrical air conditioner compressor requires a different

refrigerant oil!

For capacities, see workshop manual for specific vehicle.

Electrical air conditioner compressor

WARNING

Danger of short circuit

The air conditioner compressor operates with 288 volts and at

a speed range of 800 to 8,600 rpm.

Do not touch air conditioner compressor when drive units are

starting. Danger of short circuit!

The air conditioner compressor draws refrigerant gas from the

evaporator, compresses it and sends it to the condenser.

Note

♦ The air conditioner compressor contain^l^ks refrigerant oil, which

is miscible with R134a refrigerant at all temperatures.

♦ The maker's nameplate states the refrigerant for which the air

conditioner compressor is suitable. The flow rate is controlled

via the engine speed.

♦ The engine should be started only when the refrigerant circuit

has been fully assembled ⇒ page 14 .

♦ 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

3

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

pressor.

♦ The air conditioner has a pressure relief valve.

2.1.6

Condenser

The condenser transfers heat from the compressed refrigerant

gas to the surrounding air.

This allows the refrigerant gas to condense into liquid form.

2. General information on refrigerant circuit

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Air conditioning system with refrigerant R134a - Edition 10.2014

2.1.7

Evaporator

The liquid refrigerant evaporates in the tubes of the evaporator.

The latent heat of evaporation is taken from the air streaming past

the evaporator fins. The air cools. The refrigerant evaporates and

is drawn into the air conditioning system compressor carrying with

it the heat it has absorbed.

A restrictor or an expansion valve allows a defined quantity of

refrigerant to flow to the evaporator. In systems with an expansion

valve, the flow is regulated such that only gaseous refrigerant ex‐

its the evaporator.

2.1.8

Reservoir

The reservoir collects the vaporised and gaseous mixture coming

from the evaporator to ensure the air conditioner compressor re‐

lk

ceives only gaseous refrigerant. Gaseous refrigerant is formed

from the vapour.

Refrigerant oil flowing in the circuit does not remain in the reser‐

voir, as an oil extraction hole has been provided.

Moisture which has entered the refrigerant circuit during repairs

will be collected by a filter (dryer bag) in the reservoir.

Gaseous refrigerant with oil is drawn in by the air conditioner

compressor.

Note

♦ Renew the reservoir if the refrigerant circuit has stood open

for any length of time (more than the normal repair time) and

moisture has entered the system, or if it is required because

of a specific complaint ⇒ page 159 .

♦ Do not remove sealing plugs -A- and -B- until just before in‐

stallation.

♦ The dryer bag in an unsealed reservoir will become saturated

with moisture within a short time and is then unusable.

♦ When installing, observe arrow indicating direction of flow, if

applicable.

22

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

2.1.9

Restrictor

The restrictor creates a restriction. This restriction limits the flow,

separating the high-pressure and low-pressure sides in the re‐

frigerant circuit. Upstream of the restrictor, the refrigerant is warm

due to the high pressure. Downstream of the restrictor, the refrig‐

erant is cold due to the low pressure. Upstream of the narrow point

is a strainer to catch dirt and downstream of the narrow point is a

strainer to atomise the refrigerant before it enters the evaporator.

Note

♦ Arrow -A- on the restrictor points to the evaporator.

♦ Renew it every time the refrigerant circuit is opened.

♦ Observe different versions.

lk

⇒ Rep. gr. 87

⇒ Parts catalogue

2.1.10

Receiver

The receiver collects the liquid droplets and directs them in a

continuous stream to the expansion valve. Moisture which has

entered the refrigerant circuit during assembly is collected by the

dryer bag in the receiver.

Note

♦ Renew the receiver if the refrigerant circuit has stood open for

any length of time (more than the normal repair time) and

moisture has entered the system, or if it is required because

of a specific complaint ⇒ page 159 .

♦ Do not remove sealing plugs until just before installation.

♦ The dryer bag in an unsealed receiver will become saturated

with moisture within a short time and is then unusable.

♦ When installing, observe arrow indicating direction of flow, if

applicable.

The new generation of receivers are mounted directly on the con‐

denser and contain a dryer cartridge.

Note

♦ Renew the dryer cartridge if the refrigerant circuit has stood

open for any length of time (more than the normal repair time)

and moisture has entered the system, or if it is required be‐

cause of a specific complaint ⇒ page 159 .

♦ Remove the dryer cartridge from its packaging only immedi‐

ately before installing it.

♦ A dryer cartridge in unsealed packaging will become saturated

with moisture within a short time and is then unusable.

2. General information on refrigerant circuit

23

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

Air conditioning system with refrigerant R134a - Edition 10.2014

2.1.11

Expansion valve

The expansion valve atomises incoming refrigerant and regulates

the flow so that, depending on the heat transport, the vapour does

not become a gas until it reaches the outlet of the evaporator.

2.1.12

O-ring

These O-rings seal the joints between the individual components

of the refrigerant circuit.

Use only seals that are resistant to refrigerant R134a and its as‐

sociated refrigerant oils. This is assured by using genuine re‐

placement parts.

⇒ Parts catalogue

O-ring:

•

Never reuse seals!

Check that diameters -a- and -b- are correct.

Before fitting a seal, coat it lightly with refrigerant oil.

lk

Note

The colour coding of O-rings for R134a refrigerant circuits has

been discontinued. Coloured and black O-rings are used.

⇒ Rep. gr. 87

⇒ Parts catalogue

2.1.13

Pipes and hoses in refrigerant circuit

The mixture of refrigerant oil and refrigerant R134a attacks certain

metals (e.g. copper) and alloys and dissolves certain hose mate‐

rials. Therefore, always use genuine replacement parts.

The hoses and pipes are held together with screwed joints or

special push-fit joints.

Note

When assembling screwed joints, be careful to comply with the

prescribed torques, and when working on push-fit joints, be care‐

ful to use the disconnection tools provided.

24

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

2.1.14

High-pressure safety valve

The high-pressure safety valve is fitted to the air conditioner com‐

pressor or the receiver.

The valve opens at a pressure above approx. 38 bar and closes

again when the pressure has dropped (approx. 30 bar).

Not all the refrigerant is lost from the system.

Depending on the version, a transparent plastic disc may be fitted,

which breaks when the valve opens.

lk

2.2

Design of refrigerant circuit

2.2.1

Refrigerant circuit with expansion valve

and evaporator

1 - Evaporator

2 - Expansion valve

3 - Valve for extracting, charging and measuring

4 - Receiver with dryer bag or dryer cartridge

5 - Condenser

6 - Air conditioner compressor

Note

Arrows show the direction of refrigerant flow.

2.2.2

Refrigerant circuit with restrictor and

reservoir

1 - Air conditioner compressor

2 - Condenser

3 - Restrictor

4 - Evaporator

5 - Reservoir with dryer cartridge

Note

Arrows show the direction of refrigerant flow.

2.3

Evacuation and charging valves for

quick-release couplings of air condition‐

er service station on refrigerant circuit

Special tools and workshop equipment required

♦ Torque wrench - V.A.G 1783- (2…10 Nm) with 1/4" ratchet

adapter - VAS 6234-

2. General information on refrigerant circuit

25

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

Air conditioning system with refrigerant R134a - Edition 10.2014

WARNING

Danger of freezing injuries.

lk

If refrigerant circuit has not been evacuated, refrigerant will

escape.

Extract refrigerant before opening refrigerant circuit. If the re‐

frigerant circuit is not opened within 10 minutes after it has

been evacuated, pressure may develop in coolant circuit due

to re-evaporation. Extract refrigerant again.

•

Only valves and connections resistant to R134a refrigerant

and the related refrigerant oils may be used.

The connectors for the high-pressure and low-pressure sides

are different (outside diameter).

Always screw on sealing caps.

Arrangement within the vehicle.

See vehicle-specific repair manual ⇒ Rep. gr. 87

2.3.1

Evacuation and charging valve with

Schrader valve

Note

♦ Torque wrench - V.A.G 1783- with 1/4" ratchet adapter - VAS

6234-

♦ Appropriate insert - T10364- to remove Schrader valve core

⇒ page 172

A - Service port (soldered in)

B - Valve core (2.4 ± 0.2 Nm)

C - O-ring (for the valve)

D - Sealing cap with seal

2.3.2

Extraction and charging valve, high-

pressure side

Note

♦ Torque wrench - V.A.G 1783- with 1/4" ratchet adapter - VAS

6234-

♦ Appropriate insert - T10364- to remove valve core

⇒ page 172

1 - Base with external or internal thread

2 - O-ring: 10.8 mm; 1.8 mm identification: black or coloured

3 - Valve with M12 x 1.5 mm external thread and groove for O-

ring (7 ± 1 Nm)

4 - O-ring for cap, 10.8 mm; 1.8 mm identification: black or col‐

oured

5 - Cap

26

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

2.3.3

Extraction and charging valve, low-pres‐

sure side

Note

♦ Torque wrench - V.A.G 1783- with 1/4" ratchet adapter - VAS

6234-

♦ Appropriate insert - T10364- to remove valve core

⇒ page 172

1 - Connection with external thread and groove for O-ring

2 - O-ring: 7.6 mm; 1.8 mm identification: black or coloured

3 - Valve with M10 x 1.25 mm external thread and groove for

O-ring (7 ± 1 Nm)

4 - O-ring for cap, 7.6 mm; 1.8 mm identification: black or col‐

oured

5 - Cap

2.4

Switch and sender in refrigerant circuit

and related connections

Note

See vehicle-specific refrigerant circuit for switching pressures,

removing and fitting switches, together with switch arrangement

and versions.

lk

⇒ Rep. gr. 87

2.4.1

High-pressure switch for air conditioning

system - F23-

Function:

Switches radiator fan to next higher speed when pressure increa‐

ses in refrigerant circuit (approx. 16 bar).

2. General information on refrigerant circuit

27

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

Air conditioning system with refrigerant R134a - Edition 10.2014

2.4.2

High-pressure switch for magnetic

clutch - F118-

Function:

In the event of excess pressure in the refrigerant circuit, switches

the air conditioner compressor off (at approx. 32 bar).

2.4.3

Low-pressure switch for air conditioning

system - F73-

Function:

In the event of pressure loss in the refrigerant circuit, switches the

air conditioner compressor off (at approx. 2 bar).

lk

2.4.4

Connections to valves for switches in

the refrigerant circuit

WARNING

Danger of freezing injuries.

If refrigerant circuit has not been evacuated, refrigerant will

escape.

The refrigerant must be extracted before the valve -C- is re‐

moved. If the refrigerant circuit is not opened within 10 minutes

after it has been evacuated, pressure may develop in coolant

circuit due to re-evaporation. Extract refrigerant again.

•

The switches on the high-pressure and low-pressure sides

have different threads.

Use only valves and O-rings that are resistant to refrigerant

R134a and its associated refrigerant oils.

A - Connection (soldered in)

B - O-ring

C - Valve (with O-ring)

28

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

2.4.5

Air conditioning system pressure switch

- F129-

This pressure switch has 3 functions:

1. Switches radiator fan to next higher speed when pressure in‐

creases in refrigerant circuit (approx. 16 bar).

2. Switches the air conditioning system off in the event of excess

pressure (approx. 32 bar) (e.g. because of lack of engine cooling).

3. Switches the air conditioning system off in the event of insuffi‐

cient pressure (approx. 2 bar) (e.g. because of loss of refrigerant).

Note

lk

The air conditioning system pressure switch - F129- replaces the

high-pressure switch for air conditioning system - F23- , the low-

pressure switch for air conditioning system - F73- and the high-

pressure switch for magnetic clutch - F118- .

2.4.6

High-pressure sender - G65-

This high-pressure sender - G65- is fitted in place of the air con‐

ditioning system pressure switch - F129- .

When voltage is applied to the high-pressure sender, it generates

a square wave signal, or data telegram. This signal changes when

the pressure in the system changes.

Using this signal, the control units that are connected in-line (ra‐

diator fan control unit, engine control unit, operating and display

unit for Climatronic air conditioning system - E87- or Climatronic

control unit - J255- etc.) calculate the pressure in the refrigerant

circuit and actuate the radiator fan, the engine, the air conditioning

system magnetic coupling - N25- accordingly and/or alter actua‐

tion from the air conditioning system compressor regulating valve

- N280- .

2.4.7

Refrigerant pressure and temperature

sender - G395-

WARNING

Danger of freezing injuries.

If refrigerant circuit has not been evacuated, refrigerant will

escape.

The refrigerant must be extracted before removing the refrig‐

erant pressure and temperature sender - G395- . If the refrig‐

erant circuit is not opened within 10 minutes after it has been

evacuated, pressure may develop in coolant circuit due to re-

evaporation. Extract refrigerant again.

2. General information on refrigerant circuit

29

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

Air conditioning system with refrigerant R134a - Edition 10.2014

This refrigerant pressure and temperature sender - G395- is fitted

in place of the high-pressure sender - G65- or air conditioning

system pressure switch - F129- .

The pressure signal is monitored continuously, whereas the tem‐

perature signal is monitored only at temperatures greater than 0°

C.

The Climatronic control unit - J255- works with this information

and controls the coolant radiator fans accordingly and actuates

the air conditioning system compressor regulating valve - N280- .

2.4.8

Air conditioner compressor regulating

valve - N280-

The regulating valve is fitted to the air conditioner compressor. It

is activated by the operating and display unit for Climatronic air

conditioning system - E87- or the Climatronic control unit - J255-

The regulating valve influences the pressure in the low-pressure

side and thus the temperature at the evaporator.

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Note

The air conditioner compressor regulating valve - N280- is an in‐

tegral part of the air conditioner compressor and cannot be re‐

newed individually.

2.5

Electrical components not installed in

refrigerant circuit

2.5.1

Control and regulating unit for air condi‐

tioning system - J127-

This control and regulating unit switches off the refrigerant flow

through the second evaporator if the temperature at the cooling

fins of the second evaporator falls to the freezing point of water

(icing protection).

2.5.2

Radiator fan control unit - J293-

Note

Available in various designs, sometimes separately.

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This control unit switches the magnetic clutch and thus the air

conditioner compressor on and off. It controls the radiator fan, and

for vehicles with high-pressure sender - G65- or refrigerant pres‐

sure and temperature sender - G395- , it calculates the pressure

in the refrigerant circuit.

2.5.3

Radiator fan control unit - J293-

Note

Available in various designs, sometimes fitted to the radiator fan

-arrows-.

This control unit switches the magnetic clutch and thus the air

conditioner compressor on and off. It controls the radiator fan, and

for vehicles with high-pressure sender - G65- or refrigerant pres‐

sure and temperature sender - G395- , it calculates the pressure

in the refrigerant circuit.

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2.5.4

Temperature switch for evaporator -

E33-

Function:

The temperature switch for evaporator - E33- senses the tem‐

perature between the cooling fins of the evaporator. It prevents

the possibility of ice forming between the evaporator cooling fins

by interrupting the current to the air conditioner compressor mag‐

netic clutch if the temperature at the fins falls to the freezing point

of moisture in the air.

The insertion depth of the sensor tube is marked on the device or

is given in the repair manual ⇒ Rep. gr. 87 .

Note

Fitted to VW vehicles with air conditioning systems driven by V-

belt

2. General information on refrigerant circuit

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2.5.5

Evaporator output temperature sender -

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G263- or evaporator temperature sen‐

sor - G308-

Function:

The evaporator output temperature sender - G263- or evaporator

temperature sensor - G308- reads the temperature downstream

from the evaporator. This value is transmitted to the air condi‐

tioning system control unit and serves as a reference signal for

regulating the air conditioner compressor. This prevents icing of

the evaporator.

2.6

Pressures and temperatures in the re‐

frigerant circuit

WARNING

When working on the refrigerant circuit, observe generally ap‐

plicable safety rules and the Regulations for Pressure Tanks.

The pressures and temperatures in the refrigerant circuit depend

on the momentary operating conditions (e.g. engine speed, speed

1, 2, or 3 of radiator fan, engine temperature, whether air condi‐

tioner compressor is on or off) as well as environmental influences

(e.g. ambient temperature, humidity, required cooling output).

In vehicles with air conditioner compressor regulating valve -

N280- , the pressure on the low-pressure side is varied by acti‐

vating the valve.

Therefore, the values given in the following tables may only be

considered as guidelines. They occur at an engine speed of 1,500

to 2,000 rpm and an ambient temperature of 20°C after about 20

minutes.

The locations of connections provided for pressure measure‐

ments can be found in the vehicle-specific coolant circuits.

⇒ Rep. gr. 87

At 20°C and with the engine stopped, the refrigerant circuit will

adjust itself to a pressure of 4.7 bar positive pressure ⇒ page 3 .

2.7

Refrigerant circuit with expansion valve

A- low-pressure side of the refrigerant circuit.

B- high-pressure side of the refrigerant circuit.

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Component

Overall state

of the refriger‐

ant

Pressure (in bar)

approx. 1.2 bar¹⁾

Temperature in degrees

Celsius

-1- evaporator, from inlet to Vapour

outlet

approx. -7°C²⁾

(approx. 1.8 bar)³⁾

approx. 1.2 bar¹⁾

approx. -1°C³⁾

approx. -1℃

-2- Air conditioning system

compressor A-side

Gas

(approx. 1.8 bar)³⁾

approx. 14 bar

(approx. +1°C)³⁾

approx. +65℃

-3- Air conditioning system

compressor B-side

Gas

-4- Condenser

Gas, vapour, approx. 14 bar

liquid

at outlet approx. + 55°C

-5- Receiver

Liquid

approx. 14 bar

approx. +55℃

-6- Extraction and charging Liquid

valve, B side

-7-Expansion valve

Liquid, re‐

approx. 14 bar

approx. +55°C, reduced

to -7°C

leased into

vapour

-8- Extraction and charging Gas

approx. 1.2 bar¹⁾

approx. -7°C²⁾

valve, A side

2. General information on refrigerant circuit

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Component

Overall state

of the refriger‐

ant

Pressure (in bar)

Temperature in degrees

Celsius

(approx. 1.8 bar)³⁾

approx. -1°C³⁾

1) The pressure in refrigerant circuits with regulating air conditioner compressor is held to approx. 2 bar despite changing heat transport

and differing engine speeds. This applies however only within the rated range of the air conditioner compressor; if the rated range of the

air conditioner compressor is exceeded, the pressure will increase ⇒ page 127 .

2) The temperature in refrigerant circuits with regulating air conditioner compressor is held within the regulation range of the air conditioner

lk

compressor despite changing heat transport and differing engine speeds. This applies however only within the rated range of the air

conditioner compressor ; if the rated range of the air conditioner compressor is exceeded, the temperature will increase ⇒ page 127 .

3) Measured values for air conditioning systems with two evaporators

Note

♦ Air conditioning system compressors that do not self-regulate

their load are switched off by the respective control unit via the

air conditioner compressor regulating valve - N280- when an

evaporator temperature less than 0°C is sensed.

♦ In vehicles with air conditioner compressor regulating valve -

N280- , the pressure on the low-pressure side is varied by

activating the valve.

2.8

Refrigerant circuit with restrictor and reservoir

Arrows show the direction of refrigerant flow.

A- low-pressure side of the refrigerant circuit.

B- high-pressure side of the refrigerant circuit.

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Component

Overall state of

the refrigerant

Pressure (in bar)

up to 20 bar

Temperature in degrees

Celsius

-1- Air conditioning system com‐ Gas

to +70℃

pressor B-side

-2- Condenser

from gas

to +70℃

through vapour

to liquid

-3- Restrictor

-4- Evaporator

-5- Reservoir

from liquid to va‐ B-side up to 20 bar, A-side

B-side up to +60℃, A-

side warmer than -4°C

warmer than -4℃

pour greater than 1.5 bar

from vapour to greater than 1.5 bar

gas

Gas

-6- Air conditioning system com‐ Gas

pressor A-side

The pressures on the A-side are held at approx. 2 bar by the

“regulating” air conditioner compressor even at differing engine

speeds. This applies however only within the rated range of the

air conditioner compressor ; if the rated range of the air condi‐

tioner compressor is exceeded, the pressure will increase

⇒ page 127 .

2. General information on refrigerant circuit

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Note

In vehicles with air conditioner compressor regulating valve -

N280- , the pressure on the low-pressure side is varied by acti‐

vating the valve.

2.9

Test and measurement work that can be

performed using a pressure gauge

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Displays on the pressure gauge

1 - Temperature scale for refrigerant R134a CF3–CH2F or

CH2F–CF3.

2 - Pressure scale

In addition to the pressure scale, the pressure gauges can have

one or more temperature scales. The scale values for R134a are

assigned according to the vapour pressure table. Because differ‐

ent refrigerants have different vapour pressures at the same

temperature, each temperature scale is labelled for the respective

refrigerant.

2.9.1

Pressure gauges enable the following

test and measurement work

a – Pressure and temperature measurement in the refrigerant cir‐

cuit

♦ The high-pressure gauge allows the pressure and tempera‐

ture to be measured with the air conditioning system switched

on irrespective of whether this is at the outlet of the air condi‐

tioner compressor through the condenser up to the restriction

(restrictor or expansion valve).

♦ The low-pressure gauge allows the pressure and temperature

to be measured with the air conditioning system switched on

irrespective of whether this is at the restriction (restrictor or

expansion valve) through the evaporator up to the inlet to the

air conditioner compressor.

Note

The relationship between pressure and temperature shown on

the pressure gauge is valid only where the refrigerant in the circuit

is liquid or vapour, but not when it is gas. In the gaseous state,

the temperature is approx. 10°C to 30°C higher than indicated on

the pressure gauge.

b– Evidence of refrigerant in a closed container

Refrigerant R134a is present in a closed container or refrigerant

circuit if the temperature indicated on the pressure gauge corre‐

sponds to the temperature of the refrigerant (the temperature of

a standing liquid stabilises at ambient temperature).

A closed container or switched-off refrigerant circuit is empty if the

temperature indicated on the pressure gauge is below the tem‐

perature of the refrigerant.

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Note

The dependency between pressure and temperature described

on the pressure gauge no longer applies when there is no liquid

and the pressure is created by gas alone.

2.10

Air conditioner service and recycling

equipment

At present, various manufacturers offer air conditioner service

devices on the market for evacuating, cleaning and charging re‐

frigerant in vehicle air conditioning systems.

2.10.1

Classification of extraction systems in

groups

Group 3:

Portable extraction and charging devices linking the air condi‐

tioning system to a fixed compressed gas container.

The fixed compressed gas container is charged with refrigerant

or refrigerant/oil mixture. The portable extraction and charging

device is then permanently attached to the pressure vessel. In

accordance with § 3 section 5 no. 3 of the Regulations for Pres‐

sure Tanks, in this case the terms "compressed gas container"

and "pressure tank" are equivalent.

Charging devices require:

♦ no permit

♦ no checking by an authorised official, since the gas is held in

the compressed gas container, which is equivalent to a pres‐

sure tank. (Devices for filling refrigerant from these pressure

tanks into compressed gas containers that are intended for

third-party use, in turn, require licensing and they are subject

to checking by an authorised official.)

Note

The air conditioner service and recycling devices used in vehicle

workshops are Group 3 extraction and charging devices which do

not require a permit, but which can be operated only by skilled

staff. Refer to the manufacturer's documentation for instructions

on operating and maintaining these devices.

2.10.2

Charging devices that do not require a

permit

Charging devices that do not require a permit are mobile charging

devices into which pressurised gases are charged into com‐

pressed gas containers for exclusive use of one company.

Note:

Some air conditioner service devices are charging devices that

do not require a permit. When these devices are used, the refrig‐

erant is charged not into locally mobile compressed gas contain‐

ers, but into a permanently installed charging cylinder with a

visible contents gauge and float switch.

2. General information on refrigerant circuit

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Recommendation:

When surplus refrigerant is transferred for one's own require‐

ments, it is recommended that a portable charging cylinder with

visible level gauge and pressure relief valve be used.

Make sure to observe the corresponding technical rules (e.g.

TRGS 400, TRGS 402, TRGS 407, TRGS 510, TRBS 3145/

TRGS 725) when handling compressed gases and, in particular,

when filling compressed gases from one compressed gas con‐

tainer into another one.

2.11

Notes to repairs on refrigerant circuit

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WARNING

When working on the refrigerant circuit, observe generally ap‐

plicable safety rules and the Regulations for Pressure Tanks.

Caution

Non-authorised tools or materials (e.g. leak inhibitor additive)

may cause damage or adversely influence the system.

Only tools and materials approved by the manufacturer may

be used.

Use of non-approved tools or materials will render the warranty

void.

Special tools and accessories:

To ensure a correct and professional repair to an air conditioning

system:

•

Special tools and materials are required; these are listed on

⇒ page 165 .

The essential information on the leak detector should be re‐

ferred to ⇒ page 58 .

Expert knowledge is necessary.

Note

Releasing refrigerant into the environment is not permitted

⇒ page 39 .

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3

Statutory texts and instructions

3.1

Statutes and regulations

lk

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

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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).

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Note

lk

♦ 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

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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

lk

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.

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♦ 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

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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)

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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

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4

Refrigerant circuit

4.1

Important repair notes on air condition‐

ing

•

Air conditioning systems designed for refrigerant R12 must not

be charged with refrigerant R134a until specific conversion

measures have been performed ⇒ page 45 .

The refrigerant oils specifically developed for R134a refriger‐

ant circuits must never be mixed with the refrigerant oils spe‐

cifically developed for R12 refrigerant circuits.

Air conditioner service stations that come into contact with re‐

frigerants may be used only for the refrigerant for which they

are intended.

Components for R134a refrigerant circuits are identified with

a legend or a green label, or are so designed (e.g. with different

threads), that they cannot be confused with components for

R12 refrigerant circuits.

•

Within the engine compartment, on the bonnet catch striker

plate or in the plenum chamber there is an information plate

which states what refrigerant is used.

Different refrigerants must never be mixed together.

Note

When working on the refrigerant circuit please refer to the infor‐

mation listed under “Safety precautions” ⇒ page 13 and “Basic

procedures for working on refrigerant circuits” ⇒ page 14 .

4.2

Retrofitting refrigerant circuit from R12

refrigerant to R134a refrigerant

lk

Chlorofluorocarbon (CFC) is no longer used as a refrigerant in the

automotive sector.

R12Converting refrigerant circuits from refrigerant R12 to refrig‐

erant R134a and repairing the converted circuits.

⇒ Repair manual for air conditioning systems with refrigerant R12

parts 2 and 3 . This workshop manual is only available as a hard

copy.

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5

Working with the air conditioner serv‐

ice station

Caution

♦ If there is evidence to suggest that chemical substances

have been added in the vehicle to seal leaks, do not con‐

nect the air conditioner service station and do not extract

the refrigerant.

♦ Chemical substances used to seal leaks form deposits in

the refrigerant circuit. These can impair the function of the

air conditioning system and cause the air conditioning

system (and your air conditioner service station) to fail.

♦ Make your customer aware of the fact that there are sub‐

stances in his/her air conditioning system that do not have

VW approval. This air conditioning system cannot be

drained or repaired by you.

Note

♦ Volkswagen AG does not authorise the use of chemical sub‐

stances (leak inhibitor additives) for purposes of sealing leaks

lk

in refrigerant circuits. There are currently no permanent, ef‐

fective or material compatible tests that guarantee never caus‐

ing damage or malfunctions in an air conditioning system or

air conditioner service station.

♦ The leak inhibitor additives currently available on the market

have differing physical and chemical characteristics that may

subsequently affect the function of the air conditioning system

and air conditioner service station or even cause a total failure.

♦ Volkswagen rejects the use of chemical substances for pur‐

poses of sealing leaks in refrigerant circuits.

♦ Chemical substances used for sealing leaks in refrigerant cir‐

cuits often react with the surrounding air and the humidity

contained within. They cause deposits to build up in the re‐

frigerant circuit (and your air conditioner service station),

valves to malfunction and defects in other components with

which they come into contact. These deposits cannot be com‐

pletely removed from the components.

♦ It is often not possible to detect from the outside whether

chemical substances have been used to seal leaks in the re‐

frigerant circuit. The adhesive label that serves to identify its

use can usually not be found. Therefore, exercise caution on

vehicles for which you have no service or repair record.

♦ Containers or tanks are offered as accessories on the open

market that are designed to separate these chemical substan‐

ces (to seal leaks). Since Volkswagen rejects the use of these

substances, no statement can be made at this point regarding

the effectiveness and separation rate of these filters.

5. Working with the air conditioner service station

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5.1

Important notes for working with the air

conditioner service station

To operate the air conditioner service station - VAS 6007A- , the

following must be observed (also applies to other and latest avail‐

able air conditioner service stations).

⇒ Workshop equipment

•

The fitted filter and dryer must be renewed at the latest when

the operational time specified in the related operating instruc‐

tions has been reached.

lk

Fill only with refrigerant oils which have been approved for the

vehicle-specific refrigerant circuit.

⇒ Parts catalogue

Refrigerant that has been extracted may not be reused, even after

cleaning within the station, in any of the following circumstances:

•

If there is damage to the air conditioner compressor, such that

decomposition of the refrigerant due to overheating might

have occurred.

•

If there are dark sticky deposits in the refrigerant circuit (these

can be detected only by opening up the system).

If there is any doubt about the composition of the refrigerant

extracted from the refrigerant circuit.

In all of these circumstances the air conditioner service station

must be drained ⇒ page 49 , the system must be cleaned if

necessary, the filter and dryer and also the refrigerant oil must be

renewed.

Contaminated refrigerant can, e.g. in the Federal Republic of

Germany, be returned to the supplier in so-called recycling bottles

for recycling or for environmentally sound disposal (in other coun‐

tries other or additional regulations may apply).

Commercially available air conditioner service stations can be

divided into 2 groups:

♦ A. Air conditioner service stations that clean the extracted re‐

frigerant for reuse (so-called evacuating and recycling sta‐

tions) e.g. air conditioner service station - VAS 6007A- .

♦ B. Air conditioner service stations, called extraction stations,

that charge the extracted refrigerant into recycling bottles (for

reprocessing in bulk).

5.2

Connecting air conditioner service sta‐

tion for measuring and checking

•

Depending on the type of equipment chosen, there may be

variations in the required procedure; therefore always follow

the user's manual for the equipment being used.

Note

Always follow the procedure described in the user's manual for

your air conditioner service station - VAS 6007A- (or later model).

To prevent air or moisture from entering the refrigerant circuit

through the charging hoses, they must be connected after the

following procedure:

– Switch off ignition.

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– Connect air conditioner service station to power supply.

– Unscrew the sealing caps from the service connections, or

unscrew the connections with the valve (see vehicle-specific

refrigerant circuit).

⇒ Rep. gr. 87

– Evacuate charging hose.

lk

Note

Connect the charging hose to the service connections of the re‐

frigerant circuit using quick-release couplings.

Caution

Do not open the valves in the low- or high-pressure sides when

the engine is running. Otherwise, if the air conditioning is

switched on, the air conditioner compressor or the air condi‐

tioner service station may be destroyed by a “short circuit”

between the high- and low-pressure sides of the refrigerant

circuit.

– Turn hand wheel into quick-release coupling adapter until the

valve in the service connection is definitely open (observe

pressure gauge; do not over-tighten valve).

– Start the engine and perform the planned tests and measure‐

ments.

– Compare determined values with specifications ⇒ page 127 .

– Before disconnecting the quick-release coupling, close it by

turning out the handwheel.

5.3

Draining refrigerant circuit using air con‐

ditioner service station

WARNING

High-voltage on high-voltage system. Danger of electric shock

on air conditioner compressor!

Models with a high-voltage system: now de-energise the high-

voltage system ⇒ Electric drive; Rep. gr. 93 ; De-energising

the high-voltage system .

•

Depending on the type of equipment chosen, there may be

variations in the required procedure (always follow user's man‐

ual for the equipment being used).

The refrigerant circuit must be discharged if parts of the re‐

frigerant circuit must be removed, if there is uncertainty about

the quantity of refrigerant in the circuit or if safety measures

require it.

•

All important operating instructions associated with the air

conditioner service station for working with refrigerants can be

found in the air conditioner service station operator's manual.

Discharging:

– Switch off ignition.

5. Working with the air conditioner service station

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– Connect air conditioner service station to service connections

as described in the user's manual for the vehicle ⇒ Rep. gr.

87 and bring into operation.

Note

♦ The possibility cannot be excluded that, along with the refrig‐

erant, refrigerant oil is extracted from the refrigerant circuit. In

order to ensure the lubrication of the air conditioner compres‐

sor, the refrigerant oil quantity should be topped up with fresh

oil ⇒ Rep. gr. 87 .

♦ On vehicles with air conditioner compressor and no magnetic

coupling (with air conditioner compressor regulating valve -

N280- ) the engine should only run for < 10 minutes with empty

refrigerant circuit and closed refrigerant circuit (the air condi‐

tioner compressor runs with it continually). The engine speed

must not exceed 2000 rpm.

♦ On vehicles with air conditioner compressor and magnetic

lk

coupling, the engine may be started as the air conditioning

system pressure switch - F129- or high-pressure sender -

G65- (checks whether refrigerant is in the circuit) switches off

the magnetic coupling as soon as there is no refrigerant in the

refrigerant circuit.

5.4

Evacuating refrigerant circuit using air

conditioner service station

•

Always follow the procedure described in the user's manual

for your air conditioner service station.

The procedure described here is that for air conditioner service

station - VAS 6007A- .

Before the refrigerant circuit is charged with refrigerant, it should

be evacuated (air empty) for 45 minutes for single evaporator

system and 60 minutes for 2 evaporator systems. In addition, all

moisture should be extracted from the circuit.

Leakage can be determined when evacuating the refrigerant cir‐

cuit.

Evacuating:

Caution

♦ The engine must not be started during the evacuation pro‐

cedure and as long as there is a vacuum present in the

refrigerant circuit.

♦ The air conditioner compressor may be damaged if the

engine is started when a vacuum is present in the refrig‐

erant circuit.

♦ Only start engine when refrigerant circuits are charged.

– Switch off ignition.

– If necessary, check the refrigerant oil quantity in the refrigerant

circuit; see vehicle-specific repair manual ⇒ Rep. gr. 87 .

– Connect air conditioner service station to power supply.

– Check the refrigerant quantity in the air conditioner service

station.

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– Connect the charging hose of the air conditioner service sta‐

tion to the vehicle refrigerant circuit using quick-release cou‐

pling adapters (see vehicle-specific refrigerant circuit).

⇒ Rep. gr. 87

– Turn the handwheel of the quick-release coupling adapter far

enough inwards to ensure that the valves on the service con‐

nections are open (do not overstress the valve).

Note

Where a vehicle has a service connection on only one side of the

refrigerant circuit, if the system pressure has to be measured after

charging, use the valve adapter and charging hose with valve

opener.

– Initiate the vacuum phase on the air conditioner service sta‐

tion. The refrigerant circuit will be evacuated automatically

(observe preset evacuation period).

lk

When the vacuum phase has been completed, the leakage test

of the refrigerant circuit will start. The displays show the vacuum

in bar and the time in seconds.

If the vacuum is not maintained, proceed as follows:

– Initiate the vacuum phase on the air conditioner service station

again. The refrigerant circuit will be evacuated automatically

(observe preset evacuation period). Observe vacuum gauge

for a longer period. Charging may be done only when vacuum

is maintained.

♦ If a leak is present of a magnitude where air enters during the

evacuation phase so that the air conditioner service station

cannot create sufficient vacuum or the vacuum gauge indi‐

cates an ingress of air so that the vacuum collapses immedi‐

ately after switching off the air conditioner service station.

– Search for the leak in the refrigerant circuit as follows:

⇒ page 55

5.5

Charging refrigerant circuit using air

conditioner service station

WARNING

High-voltage on high-voltage system. Danger of electric shock

on air conditioner compressor!

Models with a high-voltage system: now de-energise the high-

voltage system ⇒ Electric drive; Rep. gr. 93 ; De-energising

the high-voltage system .

•

Always follow the procedure described in the user's manual

for your air conditioner service station.

Before charging the refrigerant, check the refrigerant oil quan‐

tity ⇒ Rep. gr. 87 .

The entire refrigerant charging quantity can be introduced ei‐

ther into the high-pressure or the low-pressure side.

Charging the refrigerant circuit

– Switch off ignition.

– Evacuating refrigerant circuit using air conditioner service sta‐

tion ⇒ page 50 .

5. Working with the air conditioner service station

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Air conditioning system with refrigerant R134a - Edition 10.2014

– Turn handwheel of quick-release coupling adapters outwards

(close).

– Allow refrigerant to flow into charging hose.

– Turn handwheel of quick-release coupling adapter inwards (do

not overstress the valve) and charge system with prescribed

quantity of refrigerant.

– Switch off air conditioner service station.

Note

If the air conditioner compressor was removed, the V-belt pulley /

freewheel must be turned by hand approx. 10 times prior to initial

operation. This does not apply for the electrical air conditioner

compressor. This prevents any damage occurring from a fluid

hammer in the air conditioner compressor when the air condition‐

ing system is switched on for the first time. If there is oil in the

cylinder of the air conditioner compressor, it will be forced out by

the rotation.

– Start with engine with air conditioner compressor switched off

(if it is the type with a magnetic clutch).

– Set air conditioner compressor to lowest possible setting; se‐

lect "ECON" mode or "A/C Off" (if version without magnetic

clutch, but with regulating valve).

– Wait until idling speed has stabilised.

– Switch air conditioner compressor on and let system run for at

least 2 minutes with engine idling.

lk

– If necessary, check pressures in refrigerant circuit using air

conditioner service station.

– Switch off engine.

– Turn out handwheel on quick-release coupling adapter.

– Detach the charging hose from the refrigerant circuit.

– Screw on sealing caps again.

5.6

Bringing air conditioning system into

service after charging

Note

If the air conditioner compressor was removed, the V-belt pulley /

freewheel must be turned by hand approx. 10 times prior to initial

operation. This prevents any damage occurring from a fluid ham‐

mer in the air conditioner compressor when the air conditioning

system is switched on for the first time. If there is oil in the cylinder

of the air conditioner compressor, it will be forced out by the ro‐

tation.

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– Start with engine with air conditioner compressor switched off

(if it is the type with a magnetic clutch).

– Set air conditioner compressor to lowest possible setting; se‐

lect "ECON" mode or "A/C Off" (if version without magnetic

clutch, but with regulating valve).

– Wait until idling speed has stabilised.

lk

– Switch air conditioner compressor on and let system run for at

least 2 minutes with engine idling.

– If necessary, check pressures in refrigerant circuit using air

conditioner service station.

– Switch off engine.

– Turn out handwheel on quick-release coupling adapter.

– Detach the charging hose from the refrigerant circuit.

– Screw on sealing caps again.

5.7

Charging container in air conditioner

service station with refrigerant

•

Always follow the procedure described in the user's manual

for your air conditioner service station.

For every air conditioning system, a certain amount of refrig‐

erant is prescribed as the required charge To ensure that the

system is neither overcharged nor undercharged with refrig‐

erant (both circumstances will impair the function of the air

conditioning system), the refrigerant container is on a weigh‐

ing machine.

5.8

Draining air conditioner service station

Note

♦ If it becomes necessary to drain the air conditioner service

station (e.g. because contaminated refrigerant was extracted),

all filters and dryers are to be renewed as a rule. Do not take

the filters and dryers out of their airtight packaging until im‐

mediately prior to installation in order to keep moisture ab‐

sorption (hygroscopic property) as low as possible.

♦ Refrigerant bottles that have been charged with contaminated,

used refrigerant are referred to as “recycling bottles”.

♦ Recycling bottles must be evacuated as a rule before being

filled for the first time with refrigerant. Refrigerant bottles that

have air in them must not be filled with refrigerant.

♦ Different types of refrigerants must not be mixed with each

other. Mixed refrigerants cannot be processed for reuse. They

have to be disposed of. If the composition of the contents of

the bottle is uncertain, the refrigerant recycler must be in‐

formed of this.

5. Working with the air conditioner service station

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WARNING

♦ When charging recycling bottles (compressed gas con‐

tainers), observe existing regulations, technical rules and

laws.

♦ Never overcharge recycling bottles. The gas cushion (ex‐

pansion space) of overcharged recycling bottles is too

small to accommodate expansion of the fluid caused by a

rise in temperature. There is a risk that the bottle will burst.

lk

♦ For your own safety, use only recycling bottles with a built-

in safety release valve.

♦ Recycling bottles must be weighed on a calibrated scale

while being charged. The maximum permitted charge

quantity is 75% (fill factor 0.75) of the charge weight shown

on the recycling bottle (the possibility cannot be excluded

that along with the refrigerant, refrigerant oil is drawn into

the recycling bottle).

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6

Detecting leaks in refrigerant circuit

Note

♦ Different processes are described in this workshop manual for

leak detection in the refrigerant circuit. These processes have

been tested and lead to a positive result under the different

conditions of use if the application is carried out correctly and

in accordance with the complaint.

lk

♦ When leak detection using compressed air/nitrogen or vac‐

uum does not produce results, use electronic leak detector or

UV leak detector additive.

♦ Small leaks can be detected with, for example, an electronic

leak detector or a UV leak detector lamp.

♦ A wide range of processes are offered on the open market for

finding leaks in refrigerant circuits. These processes do not

always produce conclusive results. If they are not used pre‐

cisely according to the specifications, they may even cause

components of the refrigerant circuit to develop leaks where

there were none before. Furthermore, certain processes can

cause preliminary or permanent damage to the components

of the refrigerant circuit

♦ Components that are found to be leaking must not be repaired.

They have to be replaced with genuine parts.

♦ A leaking refrigerant circuit must not be charged with refriger‐

ant, therefore evacuate an empty refrigerant circuit and check

for leaks before charging the system with refrigerant

⇒ page 50 .

Caution

♦ If there is evidence to suggest that chemical substances

have been added in the vehicle to seal leaks, do not con‐

nect the air conditioner service station and do not extract

the refrigerant.

♦ Chemical substances used to seal leaks form deposits in

the refrigerant circuit. These can impair the function of the

air conditioning system and cause the air conditioning

system (and your air conditioner service station) to fail.

♦ Make your customer aware of the fact that there are sub‐

stances in his/her air conditioning system that do not have

VW approval. This air conditioning system cannot be

drained or repaired by you.

6. Detecting leaks in refrigerant circuit

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Note

♦ Volkswagen rejects the use of chemical substances for pur‐

poses of sealing leaks in refrigerant circuits.

♦ Chemical substances used for sealing leaks in refrigerant cir‐

cuits often react with the surrounding air and the humidity

contained within. They cause deposits to build up in the re‐

frigerant circuit (and your air conditioner service station),

valves to malfunction and defects in other components with

which they come into contact. These deposits cannot be com‐

pletely removed from the components (not even by purging).

♦ It is often not possible to detect from the outside whether

chemical substances have been used to seal leaks in the re‐

frigerant circuit. The adhesive label that serves to identify its

use can usually not be found. Therefore, exercise caution

when working on vehicles for which you have no service or

repair record.

♦ Containers or tanks are offered as accessories on the open

market that are designed to separate these chemical substan‐

ces (to seal leaks). Since Volkswagen rejects the use of these

substances, no statement can be made at this point regarding

the effectiveness and separation rate of these filt_le_krs.

6.1

Leak detection in refrigerant circuit us‐

ing compressed air or nitrogen

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Note

♦ A leak in the refrigerant circuit can be detected, for example,

by pressurising the circuit to a maximum of 15 bar using

cleaned and dried compressed air or nitrogen ⇒ page 65 . If

the leak is large, the leakage point can be detected by sound

as the air or gas escapes.

♦ Introduce the compressed air or the nitrogen through the serv‐

ice connection.

♦ The quick-release coupling adapter for service connection can

be fitted with a modified charging hose -A- (e.g. with a 5/8"-18

UNF thread, depending on the thread of the quick-release

coupling adapter) and a suitable adapter -B- to connect to the

workshop compressed air system ⇒ page 174 . To ensure no

moisture, oil or other contaminants can enter the refrigerant

circuit from the workshop compressed air system, use, for ex‐

ample, a supplementary combination fine filter element with

an oil, dirt and water separator as normally used in paint

shops. Install it between the compressed air system and the

charging hose -A- ⇒ Workshop equipment catalogue .

♦ Using the manifold gauge with pressure reducer for nitrogen

(maximum reduced pressure: 15 bar) -1- you can connect a

full nitrogen gas cylinder -3- via a charging hose -2- (e.g. with

5/8"-18 UNF threaded connection) to the service connection,

to which a quick-release coupling adapter is connected, of a

closed refrigerant circuit. ⇒ page 174

– Slowly increase pressure in refrigerant circuit to a maximum

of 15 bar.

lk

WARNING

♦ Maximum permissible working pressure: 15 bar

♦ When searching for leaks using nitrogen, work only with a

pressure reducer for nitrogen cylinders.

– Search for leak by sound, which is created by the escaping

gas. Use Ultrasonic tester - V.A.G 1842- to ease localisation

of sounds.

– Press nitrogen out of refrigerant circuit using cleaned and

dried compressed air. Nitrogen must not enter the service cyl‐

inder. This prevents the service cylinder from being filled with

condensable gases.

– Rectify leak.

– Evacuate again and observe the vacuum display over a period

of hours. Charging may be done only when vacuum is main‐

tained.

♦ If a leak is present of a size where no or very little air is drawn

in and the air conditioner service station can create sufficient

vacuum. The vacuum gauge does not increase or increases

very slowly after switching the air conditioner service station

off, this indicates there may be a very small ingress of air and

the vacuum is lost.

– Charge circuit with 100 g of refrigerant and search for the pos‐

sible leak using an electronic leak tester and rectify fault as

necessary ⇒ page 58 or add an approved UV contrast sub‐

stance to the refrigerant and search for the possible leak in the

circuit using leak detector system VAS 6201 or later model and

rectify fault as necessary ⇒ page 59 .

6. Detecting leaks in refrigerant circuit

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– Evacuating refrigerant circuit if necessary ⇒ page 49

– Evacuate refrigerant circuit and observe the vacuum gauge

over a period of hours. Charging may be done only when vac‐

uum is maintained.

6.2

Searching for leaks in refrigerant circuits

using leak detector - V.A.G 1796-

lk

Note

Small leaks can be detected with, for example, an electronic leak

detector.

– 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).

Leak detection:

– Prepare leak detector for operation according to its operating

instructions.

– Always hold probe tip under location of suspected leak.

If the rate of clicks rises or a howl occurs, depending on model, a

leak has been found (see operating instructions for leak detector).

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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

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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.

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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

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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.

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– 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

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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.

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Air conditioning system with refrigerant R134a - Edition 10.2014

7

Clearing refrigerant circuit of contam‐

inants

7.1

Blowing through refrigerant circuit with

compressed air and nitrogen

•

Use compressed air to force moisture and other contaminants

out of the refrigerant circuit and use nitrogen to force moisture

out of the refrigerant circuit.

The method of blowing through the refrigerant circuit with

compressed air and nitrogen often requires a lot more work

than purging with refrigerant R134a. When purging with re‐

frigerant R134a, cleaning of the components is considerably

better. It is therefore always best to purge the system in the

event of complaints (the method of blowing through should

only be selected for certain complaints and for individual com‐

ponents).

Only individual components are to be blown through if:

♦ There is no way of purging the refrigerant circuit with refriger‐

ant R134a.

♦ If there is dirt or contamination in individual components of the

refrigerant circuit.

♦ If during evacuation of a leak-tight refrigerant circuit the vac‐

uum display is not constant on gauge (moisture in the refrig‐

erant circuit, which generates vapour pressure).^lk

♦ If the refrigerant circuit has been left open for longer than nor‐

mally required for repairs (e.g. following an accident)

♦ Pressure and temperature measurements in the circuit indi‐

cate that there is moisture in the refrigerant circuit.

♦ The vehicle-specific repair manual ⇒ Heating, air conditioning

deems it necessary after replacement of certain components.

Note

♦ Blowing through the refrigerant circuit with compressed air and

nitrogen will not achieve the same degree of cleanliness as

purging with refrigerant R134a. When purging with refrigerant

R134a, the refrigerant oil is shifted and cleaning of the com‐

ponents is better ⇒ page 67 .

♦ When blowing through, a maximum working pressure of 15 bar

must not be exceeded (if necessary, use pressure limiter for

compressed air as well).

WARNING

♦ Nitrogen can escape from the bottle in an uncontrolled

way.

♦ Work only with pressure regulator for nitrogen bottles

(max. working pressure 15 bar).

♦ The gas mixture escaping from the components must be

collected with appropriate extraction equipment.

7. Clearing refrigerant circuit of contaminants

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– Always blow through components opposite the direction of re‐

frigerant flow.

Compressed air and nitrogen cannot be blown through the re‐

strictor, expansion valve, air conditioner compressor, receiver or

reservoir.

– In cases where condensers have a drying agent cartridge in

the integrated receiver, this drying agent cartridge must be re‐

moved.

– First blow out soiling using compressed air and then dry com‐

ponents with nitrogen.

– Fit adapter for connection of pressure hose to refrigerant cir‐

cuit ⇒ page 86 and ⇒ Heating, air conditioning .

To prevent oil and moisture from the compressed air system

making its way into the refrigerant circuit, the following points must

be observed.

♦ The compressed air must be fed through a compressed air

cleaning unit to clean and dry it. Therefore, use compressed

air filter and dryer (included in items supplied with tools for

painting work) ⇒ Workshop equipment and Special tools cata‐

logue .

lk

♦ If refrigerant pipes have threads or union nuts at connections,

use adapter - V.A.G 1785/1- to adapter - V.A.G 1785/8- to

connect to 5/8" - 18 UNF charging hose. These adapters can

be found in the adapter case for VW/Audi passenger vehicle

set - VAS 6338/1- and adapter case for commercial vehicle

set - VAS 6338/50- .

♦ On refrigerant pipes without thread or union nut on the con‐

nection, use adapter from adapter case for VW/Audi passen‐

ger vehicle set - VAS 6338/1- or adapter case for commercial

vehicle set - VAS 6338/50- or proprietary air gun with rubber

nozzle.

Note

♦ Always extract any escaping air and/or nitrogen from the com‐

ponents using appropriate local exhaust ventilation LEV (e.g.

workshop extraction system).

♦ Certain contaminants and old refrigerant oil cannot be shifted

from the refrigerant circuit at all with compressed air or if the

compressed air is insufficient. These contaminants can only

be removed by purging with refrigerant R134a ⇒ page 67 .

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Air conditioning system with refrigerant R134a - Edition 10.2014

7.1.1

Blowing out refrigerant circuit

Note

♦ On vehicles where no adapters fit the refrigerant pipes, blow

through individual components using an air gun, for example,

with rubber nozzle. When doing this, be particularly careful not

to damage the connections (do not crush or scratch them).

♦ The evaporator should be blown through from the connection

to the low-pressure side (large diameter), with the expansion

valve or restrictor removed.

♦ Always blow through components opposite the direction of re‐

frigerant flow.

♦ Examine the expansion valve; renew if dirty or corroded.

lk

♦ If components bear dark, sticky deposits which cannot be re‐

moved with compressed air, renew these components.

♦ Thin, light grey deposits on the insides of refrigerant pipes do

not impair the function of the components.

♦ After blowing out the system, always renew the receiver or

reservoir and the restrictor. If the condenser has a dryer, re‐

new the dryer cartridge or dryer.

7.2

Purging (cleaning) refrigerant circuit

with refrigerant R134a

Vehicles with high-voltage system (hybrid vehicles)

Observe the additional warning instructions for working on vehi‐

cles with high-voltage system ⇒ Electrical system; Rep. gr. 93 ;

General warning instructions for work on the high-voltage sys‐

tem .

WARNING

Risk of injury due to unexpected engine start

When working on a high-voltage vehicle, switch off the ignition,

and deposit the ignition key somewhere outside the passenger

compartment.

WARNING

Handling high-voltage cables:

•

Do not support yourself or your tools on high-voltage ca‐

bles and their components --> risk of damage to the insu‐

lation.

•

High-voltage cables must not be extensively bent or

kinked --> risk of damage to the insulation.

The round high-voltage connectors are colour-coded with

a coloured ring on the outside and mechanically coded

with respective guide lugs. Always observe the coding

when connecting the round high-voltage connectors in or‐

der to prevent any mechanical damage to the high-voltage

connectors.

7. Clearing refrigerant circuit of contaminants

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DANGER!

Hazardous voltage resulting from damaged high-voltage com‐

ponents

Observe the following when working in the vicinity of high-volt‐

age components and cables:

♦ Work involving metal-removing, deforming and sharp-

edged tools or heat sources such as welding, soldering,

hot air and thermal bonding is not permitted.

♦ Before starting work, carry out a visual check on the high-

voltage components in the area of work.

♦ When working in the engine compartment, carry out a vis‐

ual check on the power and control electronics for electric

drive - JX1- , the electric drive motor - V141- , the air con‐

ditioner compressor - V470- and the high-voltage cables.

♦ When working on the underbody, carry out a visual check

on the high-voltage cables and covers.

♦ When working on the rear end, carry out a visual check on

the high-voltage cables and the maintenance connector

for high-voltage system - TW - .

♦ Carry out a visual check on all potential equalisation lines.

When carrying out the visual check, observe the following:

♦ The high-voltage components must not reveal any exter‐

nal damage.

♦ The insulation of the high-voltage cables and the potential

lk

equalisation lines must not be damaged.

♦ The high-voltage cables must not show any unusual de‐

formations.

♦ Each high-voltage component must be clearly identified

with a red warning sticker.

If repair work in the vicinity of high-voltage components and ca‐

bles is necessary, “carry out a visual check for damage on high-

voltage components and cables”, and “observe the general

warning instructions for work on the high-voltage system” ⇒ Elec‐

trical system; Rep. gr. 93 ; General warning instructions for work

on the high-voltage system .

If repair work on high-voltage components is necessary, de-en‐

ergise the high-voltage system ⇒ Electrical system; Rep. gr. 93 ;

De-energising high-voltage system , and “observe the general

warning instructions for work on the high-voltage system” ⇒ Elec‐

trical system; Rep. gr. 93 ; General warning instructions for work

on the high-voltage system .

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Caution

♦ If there is evidence to suggest that chemical substances

have been added in the vehicle to seal leaks, do not con‐

nect the air conditioner service station and do not extract

the refrigerant.

♦ Chemical substances used to seal leaks form deposits in

the refrigerant circuit. These can impair the function of the

air conditioning system and cause the air conditioning

system (and your air conditioner service station) to fail.

♦ Make your customer aware of the fact that there are sub‐

stances in his/her air conditioning system that do not have

VW approval and therefore the refrigerant circuit cannot

be purged. The refrigerant circuit can only be repaired by

replacing all components that have come into contact with

this substance.

Note

lk

♦ Volkswagen rejects the use of chemical substances for pur‐

poses of sealing leaks in refrigerant circuits.

♦ Chemical substances used for sealing leaks in refrigerant cir‐

cuits often react with the surrounding air and the humidity

contained within. They cause deposits to build up in the re‐

frigerant circuit (and your air conditioner service station),

valves to malfunction and defects in other components with

which they come into contact. These deposits cannot be com‐

pletely removed from the components (not even by purging).

The refrigerant circuit can only be repaired by replacing all

components that have come into contact with this substance.

♦ It is often not possible to detect from the outside whether

chemical substances have been used to seal leaks in the re‐

frigerant circuit. The adhesive label that serves to identify its

use can usually not be found. Therefore, exercise caution on

vehicles for which you have no service or repair record.

•

To work as cleanly as possible and avoid the task becoming

labour intensive when removing contaminants (e.g. friction

dust and particles from defective air conditioner compressor)

and old refrigerant oil, the refrigerant circuit must be purged

using refrigerant R134a.

On vehicles with electrical air conditioner compressor, observe

the notes on renewing the electrical air conditioner compressor -

V470-. If the electronics of the air conditioner compressor are

damaged, the refrigerant circuit must not always be cleaned

⇒ page 161 .

The refrigerant circuit must be purged with refrigerant R134a if:

♦ Dirt or other contaminants are in the refrigerant circuit.

♦ If during evacuation of a leak-tight refrigerant circuit the vac‐

uum display is not constant on gauge (moisture in the refrig‐

erant circuit, which generates vapour pressure).

♦ If the refrigerant circuit has been left open for longer than nor‐

mally required for repairs (e.g. following an accident).

♦ Pressure and temperature measurements in the refrigerant

circuit indicate that there is moisture in the refrigerant circuit.

♦ There is doubt about the amount of refrigerant oil in the refrig‐

erant circuit. If the air conditioner compressor is to be reinstal‐

led, drain refrigerant oil out of air conditioner compressor via

7. Clearing refrigerant circuit of contaminants

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Air conditioning system with refrigerant R134a - Edition 10.2014

the drain plug. To facilitate this process, turn the air conditioner

compressor over by hand at the poly V-belt pulley or coupling

disc of the magnetic coupling. After purging, fill refrigerant cir‐

cuit with total amount of refrigerant oil (50 g direct into air

conditioner compressor) according to ⇒ vehicle-specific work‐

lk

shop manual . Observe additional oil requirements for systems

with second evaporator.

♦ The air conditioner compressor has to be exchanged because

of internal damage (e.g. noisy or no output).

♦ the vehicle-specific repair manual deems it necessary after

replacement of certain components.

♦ a different air conditioner compressor with other refrigerant oil

is to be fitted.

Tools required

♦ Air conditioner service station with purging device - VAS 6381-

or air conditioner service station with purging device - VAS

6337- . These air conditioner service stations feature an ad‐

ditional function for “purging the refrigerant circuit with R134a”

and the purging device for refrigerant circuits necessary for

this procedure ⇒ Workshop equipment and special tools cata‐

logue .

♦ Adapter case VW/Audi passenger vehicle set - VAS 6338/1-

⇒ page 86 and ⇒ Workshop equipment and special tools

catalogue .

♦ Adapter case commercial vehicle set - VAS 6338/50-

⇒ page 86 and ⇒ Workshop equipment and special tools

catalogue .

Note

♦ If the above mentioned air conditioner service stations are not

available in the workshop, purging device for refrigerant cir‐

cuits - VAS 6336/1- or purging device for refrigerant circuits -

VAS 6337/1- can be used to purge the refrigerant circuit,

depending on the type of air conditioner service station in

service (min. 7 kg refrigerant R134a in refrigerant bottle). The

purging process must then be carried out manually

⇒ page 75 .

♦ On vehicles with threaded connections on the refrigerant cir‐

cuit, adapter - V.A.G 1785/1- to adapter - V.A.G 1785/8- from

adapter case VW/Audi passenger vehicle set - VAS 6338/1-

or adapter case commercial vehicle set - VAS 6338/50- can

be used. On vehicles with threaded connections on the air

conditioner compressor and on the reservoir, the adapter -

V.A.G 1785/8- is required two-fold.

♦ In the adapter case there is also a charging hose - VAS

6338/31- with 5/8 - 18 UNF connections and large internal di‐

ameter to bridge components (commercially available type).

Preliminary measures

– Drain refrigerant circuit ⇒ page 49 .

– Remove air conditioner compressor ⇒ Heating, air condition‐

ing .

On vehicles with restrictor and reservoir.

– Remove restrictor (vehicle-specific) and join the refrigerant

lines together again ⇒ Heating, air conditioning .

– Remove reservoir (vehicle-specific) ⇒ Heating, air condition‐

ing and join refrigerant pipes together again (to do this, use

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Air conditioning system with refrigerant R134a - Edition 10.2014

adapter and charging hose - VAS 6338/31- from adapter case

VW/Audi passenger vehicle set - VAS 6338/1- )

⇒ page 86 .

Note

The collector could be purged but due to its large inner volume it

would require too much refrigerant. During extraction, the refrig‐

erant ices up the reservoir heavily and the extraction procedure

takes much longer as a result.

On vehicles with expansion valve and receiver.

– Remove the receiver ⇒ Heating, air conditioning (vehicle-

specific, not necessary on all vehicles) and join the refrigerant

lines together (use the adapter and the charging hose - VAS

6338/31- to do this) ⇒ page 86 .

– Remove the expansion valve ⇒ Heating, air conditioning (ve‐

hicle-specific) and insert an adapter in its place ⇒ page 86 .

Note

If there is not a suitable adapter for the expansion valve in the

adapter case VW/Audi passenger vehicle set - VAS 6338/1- or

adapter case commercial vehicle set - VAS 6338/50- , the re‐

moved expansion valve can also be drilled out (the old expansion

valve must be subsequently renewed).

Caution

♦ When drilling out, ensure that the sealing surfaces on the

expansion valve are not damaged.

♦ Refrigerant would otherwise escape.

lk

7. Clearing refrigerant circuit of contaminants

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Note

♦ Before drilling out, some parts have to be removed from the

expansion valve.

♦ There are two types of expansion valve. For type -A-, parts

-B-, -C- and -D- must be removed. Separate regulator -E- from

component -D-. Then drill through expansion valve in area

-F- using a suitable 6 mm drill.

♦ On version -G-, parts -H-, -I- and -K- must be removed and

then area -L- drilled out with a suitably sized drill bit (6 mm in

lk

diameter).

♦ Clean away any swarf from the drilled out expansion valve.

♦ Reinstall parts -B-, -C- and -D- on type -A- or part -H- on type

-G-.

Note

On vehicles with two evaporators, the circuit to the second evap‐

orator must be isolated from the circuit to the first evaporator and

purged in a separate procedure ⇒ Heating, air conditioning and

⇒ page 86 .

Drill open shut-off valve.

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Note

♦ Two shut-off valves are required for purging the refrigerant

lk

circuit. A shut-off valve must be drilled open, if no shut-off tap

- VAS 6338/42- is available, for example.

♦ Remove the solenoid -A- and the solenoid valve -B- before

drilling open the shut-off valve.

♦ Drill open the shut-off valve -C- using a suitable drill bit (e.g.

5 mm in diameter).

♦ Remove any metal shavings resulting from drilling hole -D-

from shut-off valve -C-.

♦ Reinstall the solenoid valve -B- with the respective seal -E- to

the shut-off valve -C- which has been drilled open.

Purging

– Check the refrigerant volume in the air conditioning bottle.

There must be at least 7 kg of R134a refrigerant.

Note

Switch on the heater attached to the refrigerant bottle 30 minutes

before the first purging process, if necessary. In this way, pres‐

sure in the refrigerant bottle is increased and charging of the

purging circuit is accelerated.

– Drain the waste oil container of the air conditioner service sta‐

tion.

– Connect the supply hose (high-pressure side) of the air con‐

ditioner service station with an adapter ⇒ page 86 to the low-

pressure line leading to the air conditioner compressor (line

with larger diameter).

– Connect the return hose (low-pressure or suction side) of the

air conditioner service station to the outlet of the purging de‐

vice for refrigerant circuits.

– Connect the inlet of the purging device for refrigerant circuits

with an adapter ⇒ page 86 to the high-pressure line leading

to the air conditioner compressor (line with smaller diameter).

7. Clearing refrigerant circuit of contaminants

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lk

Note

♦ The components must always be purged against the direction

of refrigerant flow when the air conditioning system is in oper‐

ation (not applicable for electrical air conditioner compressor)

⇒ page 77 .

♦ When purging, contaminants from the refrigerant circuit enter

the purging device for refrigerant circuits and the air condi‐

tioner service station and are retained in the filters and dryers

installed within. Depending on the contaminants, these com‐

ponents must be changed at shorter intervals in accordance

with the operating instructions for the air conditioner service

station or purging device for refrigerant circuits.

♦ The filter in the purging device for refrigerant circuits should

be changed after about 2 purging cycles (purged vehicles),

depending on the level of contamination from the purged re‐

frigerant circuits. If a heavily contaminated refrigerant circuit is

purged (the refrigerant oil from the refrigerant circuit is black

and viscous or there are large amounts of shavings in the re‐

frigerant circuit) renew filter after purging refrigerant circuit.

After such heavy contamination of the refrigerant circuit, we

suggest purging the system again after changing the filter.

♦ Depending on the type of contamination, deposits (old refrig‐

erant oil and abrasive wear particles from the air conditioner

compressor) will gather in the sight glass(es) of the purging

device for refrigerant circuits. Clean sight glass(es) after purg‐

ing and purge refrigerant circuits again.

♦ Fluid refrigerant cannot flow at the necessary speed through

the expansion valve, the restrictor and the dryer cartridge of

certain receivers. These components must therefore be re‐

moved and an adapter installed in their place ⇒ Heating, air

conditioning .

♦ Adapters to connect air conditioner service station and to

bridge certain components of refrigerant circuit ⇒ page 86 .

– Switch on the air conditioner service station and purge the re‐

frigerant circuit (duration approx. 1 to 1.5 hours for one purging

cycle with three purgings using approx 4 Kg refrigerant

R134a).

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Air conditioning system with refrigerant R134a - Edition 10.2014

Note

lk

♦ The purging process of the refrigerant circuit should be carried

out in accordance with the operating instructions of the air

conditioner service station

♦ Depending on the type of air conditioner service station, the

3

waste oil container has a capacity of only approx. 125 cm . If

a system with a greater amount of refrigerant oil has to be

purged, it may be necessary to empty the waste oil container

after the first purge of the purging cycle.

♦ Watch the refrigerant that flows out of the refrigerant circuit.

When the refrigerant flows through the sight glass of the purg‐

ing device into the air conditioner service station clear and

completely free of colour, the refrigerant circuit is cleaned.

♦ When purging, the whole amount of refrigerant oil from the

refrigerant circuit is cleaned (except for a small amount in the

evaporator, though this is not important).

♦ Where contamination is particularly high, it may be necessary

to carry out the purging cycle twice (two purging cycles with

three purges each). Purging device filter must be renewed be‐

fore starting second purging cycle.

Sequence of purging process (sequence is carried out automati‐

cally in accordance with the air conditioner service station pro‐

gramme)

♦ After switching on, the purging cycle (refrigerant circuit with

connection hoses and purging device for refrigerant circuits)

is first evacuated and the refrigerant circuit thereby checked

for leaks. Depending on the type of air conditioner service sta‐

tion, it may be necessary to continue the sequence manually.

♦ In the evacuated purging circuit, a predetermined amount of

refrigerant is filled (e.g. 4 kg) via the high-pressure side of the

air conditioner service station (against the normal direction of

flow for air conditioner operation and thereby on the low-pres‐

sure side of the vehicle refrigerant circuit). Depending on the

type of air conditioner service station, refrigerant is filled until

the purging circuit is completely filled with liquid refrigerant.

This can be identified, for example, by the fact that after a cer‐

tain period of time no more refrigerant flows through.

♦ Once the predetermined amount of refrigerant has been filled

in the system, the heater, for example, of the purging device

for refrigerant circuits is switched on depending on the type of

air conditioner service station and purging device for refriger‐

ant circuits (only if the refrigerant is extracted in gaseous form

out of the purging device for refrigerant circuits).

♦ When the refrigerant has been extracted, the heater of the

purging device (if fitted) for refrigerant circuits is switched off,

the refrigerant circuit may have to be evacuated briefly again

depending on the design, and following evacuation so that the

air conditioner service station can separate out the refrigerant

oil.

♦ The sequence for filling with refrigerant, extracting (and evac‐

uating) is carried out twice (that means a total of three times).

♦ After extracting for the third time, the purging circuit is evacu‐

ated depending on the type of air conditioner service station.

7. Clearing refrigerant circuit of contaminants

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Air conditioning system with refrigerant R134a - Edition 10.2014

– Once the purging cycle is complete, check the sight glass (or

sight glasses) for refrigerant circuits. If this is dirty, clean it in

accordance with the operating instructions of the purging de‐

vice for refrigerant circuits or the air conditioner service station.

Carry out a purging cycle once more as a precautionary meas‐

ure. One purging cycle is sufficient (approx. 30 min.).

– Check the pressure in the refrigerant circuit. There must be no

pressure in the refrigerant circuit (evacuate again briefly if

necessary).

– Remove the connections to the air conditioning service station

from the refrigerant circuit of the vehicle (there should be no

pressure in the refrigerant circuit)

– Renew these components according to the type of vehicle.

♦ Restrictor and reservoir

♦ Expansion valve and receiver or dryer cartridge in receiver

lk

– ⇒ Heating, air conditioning and ⇒ Parts catalogue .

– Replace air conditioner compressor depending on complaint

⇒ Heating, air conditioning and ⇒ Parts catalogue or drain

the remaining refrigerant oil from the removed air conditioner

compressor ⇒ page 159 (renewing components of refrigerant

circuit) and fill it with the prescribed amount of fresh refrigerant

oil ⇒ vehicle-specific workshop manual .

Note

♦ There is a predetermined amount of refrigerant oil in the gen‐

uine air conditioner compressor. On vehicles with two evapo‐

rators, a certain amount of refrigerant oil may have to be added

to the circuit as appropriate ⇒ vehicle-specific workshop man‐

ual .

♦ If the air conditioner compressor does not have to be renewed,

the volume of refrigerant oil in the air conditioner compressor

must be replenished in accordance with the fill volume (pour

out refrigerant oil and refill the prescribed amount in the air

conditioner compressor or the refrigerant circuit)

⇒ page 159 (renewing components of refrigerant circuit) and

⇒ vehicle-specific workshop manual .

– Assemble the refrigerant circuit back together again complete‐

ly ⇒ Heating, air conditioning .

– Evacuate and fill the refrigerant circuit as per specifications

⇒ page 51 and ⇒ page 50 .

– Bring the air conditioning system into operation as per speci‐

fications ⇒ Heating, air conditioning and ⇒ page 52 .

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Air conditioning system with refrigerant R134a - Edition 10.2014

7.2.1

Principle circuit diagrams for various

purging circuits

Note

♦ The arrows in the following illustrations show the direction of

flow of the refrigerant during purging. The refrigerant flows

against the direction of flow during normal conditioning of the

air, which is why the high-pressure system of the air condi‐

tioner service station is connected to the low-pressure con‐

nection of the refrigerant circuit to the air conditioner

compressor.

♦ These principle circuit diagrams show a refrigerant circuit with

restrictor and reservoir and a refrigerant circuit with expansion

valve, receiver and a second evaporator (extra equipment on

certain vehicles).

♦ Depending on the design of the air conditioner service station,

non-return valves may be installed between the refrigerant

circuit and the air conditioner service station. This ensures the

correct direction of flow of refrigerant during purging.

Refrigerant circuit with restrictor and reservoir

lk

Note

On vehicles with restrictor and reservoir, the restrictor and the

reservoir are removed. The refrigerant pipes of the restrictor are

assembled again. The refrigerant pipes to the removed reservoir

are joined together with two adapters and the charging hose -

VAS 6338/31- (from adapter case VW/Audi passenger vehicle set

- VAS 6338/1- .

7. Clearing refrigerant circuit of contaminants

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1 - Air conditioner service sta‐

tion

❑ With electronics and a

purging programme e.g.

air conditioner service

station - VAS 6380- with

purging device or air

conditioner service sta‐

tion with purging device

- VAS 6337- .

❑ If an air conditioner

service station without

purging programme is

used, the sequence has

to be carried out man‐

ually (evacuate, purge

3 times with at least 4 kg

of refrigerant each time

and extract refrigerant

again, evacuate).

2 - Refrigerant hose of air con‐

ditioner service station

❑ From high pressure side

of air conditioner service

station (normally col‐

oured red) to connection

for low pressure side of

air conditioner compres‐

sor on refrigerant circuit

(larger diameter)

3 - Adapter to connection for

low-pressure side on refriger‐

ant circuit

lk

❑ Different versions de‐

pending on vehicle

⇒ page 86 .

❑ From adapter case VW/

Audi passenger vehicle

set - VAS 6338/1- .

4 - Connection for low-pressure side on refrigerant circuit

❑ Different versions depending on vehicle ⇒ page 86 .

❑ On refrigerant line from air conditioner compressor to reservoir

5 - Connection to reservoir

❑ Different versions depending on vehicle ⇒ page 86 .

❑ On refrigerant line from air conditioner compressor to reservoir

6 - Adapter to bridge removed reservoir

❑ Different versions depending on vehicle ⇒ page 86 .

❑ From adapter case VW/Audi passenger vehicle set - VAS 6338/1- .

7 - Charging hose for refrigerant ⇒ page 86

❑ For example charging hose - VAS 6338/31- (from adapter case VW/Audi passenger vehicle set - VAS

6338/1- ).

8 - Adapter to bridge removed reservoir

❑ Different versions depending on vehicle ⇒ page 86 .

❑ From adapter case VW/Audi passenger vehicle set - VAS 6338/1- .

9 - Connection to reservoir

❑ Different versions depending on vehicle ⇒ page 86 .

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10 - Evaporator

11 - Location of restrictor

❑ The restrictor is removed.

❑ Removing restrictor ⇒ Heating, air conditioning .

12 - Threaded connection in refrigerant line

lk

❑ After removing the restrictor, screw back together again ⇒ Heating, air conditioning .

13 - Condenser

14 - Connection for high-pressure side on refrigerant circuit

❑ Different versions depending on vehicle ⇒ page 86 .

15 - Adapter to connection for high-pressure side on refrigerant circuit

❑ Different versions depending on vehicle ⇒ page 86 .

❑ From adapter case VW/Audi passenger vehicle set - VAS 6338/1- .

16 - Charging hose of flushing device for refrigerant circuits

❑ From connection to high-pressure side of air conditioner compressor on refrigerant circuit (smaller di‐

ameter) to inlet of purging device for refrigerant circuits - VAS 6336/1- or purging device for refrigerant

circuits - VAS 6337/1- .

17 - Purging device for refrigerant circuits

❑ Different versions and different design e.g. purging device for refrigerant circuits - VAS 6336/1- or purging

device for refrigerant circuits - VAS 6337/1- .

❑ With filter, sight glass, safety valve, heating, refrigerant tank, etc. (depending on version).

❑ Depending on the design of the air conditioner service station and the purging device for refrigerant

circuits, there may be a non-return valve installed at the outlet of the purging device for refrigerant circuits

(to assure the correct direction of refrigerant flow during purging).

18 - Refrigerant hose of air conditioner service station

❑ From the low-pressure side of the air conditioner service station (normally coloured blue) to the outlet of

the purging device for refrigerant circuits

Refrigerant circuit with expansion valve, receiver and second

evaporator

Note

♦ This principle circuit diagram shows a refrigerant circuit with

expansion valve, receiver and a second evaporator (extra

equipment on certain vehicles).

♦ On vehicles with expansion valve and receiver, the expansion

valve is removed and an adapter installed in its place. The

receiver must be purged, depending on the vehicle or the dryer

cartridge removed. Depending on the type of receiver, this

should be removed and the line connections to the receiver

joined together using two adapters and a charging hose.

♦ On vehicles with just one evaporator, the components from

position “16” are not installed or not required.

7. Clearing refrigerant circuit of contaminants

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1 - Air conditioner service sta‐

tion

❑ With electronics and a

lk

purging programme e.g.

air conditioner service

station - VAS 6380- with

purging device or air

conditioner service sta‐

tion with purging device

- VAS 6337- .

❑ If an air conditioner

service station is used

which does not have a

purging programme,

then the sequence must

be performed manually.

–

Extract refrigerant, if

there is any in the sys‐

tem.

Connect purging device

for refrigerant circuits -

VAS 6336/1- or purging

device for refrigerant cir‐

cuits - VAS 6337/1- be‐

tween air conditioner

service station and re‐

turn line for refrigerant

circuit.

–

Evacuate refrigerant cir‐

cuit for 20 minutes, then

fill system with 4 kg of

refrigerant R134a. Then

extract again and repeat

process two further

times. If after the 3rd

purging process the re‐

frigerant in the sight

glass/glasses is not clear, repeat process again.

2 - Refrigerant hose of air conditioner service station

❑ From high pressure side of air conditioner service station (normally coloured red) to connection for low

pressure side of air conditioner compressor on refrigerant circuit (larger diameter)

3 - Adapter to connection for low-pressure side on refrigerant circuit

❑ Different versions depending on vehicle ⇒ page 86 .

❑ From adapter case VW/Audi passenger vehicle set - VAS 6338/1- .

4 - Connection for low-pressure side on refrigerant circuit

❑ Different versions depending on vehicle ⇒ page 86 .

5 - Adapter for removed expansion valve

❑ Different versions depending on vehicle ⇒ page 86 .

❑ From adapter case VW/Audi passenger vehicle set - VAS 6338/1- .

6 - Evaporator

7 - Connection to receiver

❑ Different versions depending on vehicle ⇒ page 86 .

❑ Not included on vehicles with a dryer cartridge in the receiver on the condenser or one in the receiver

integrated within the condenser ⇒ Heating, air conditioning .

8 - Adapter to bridge removed receiver

❑ Not required on all vehicles.

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❑ Different versions depending on vehicle ⇒ page 86 .

❑ From adapter case VW/Audi passenger vehicle set - VAS 6338/1- .

9 - Charging hose for refrigerant ⇒ page 86

❑ For example charging hose - VAS 6338/31- (from adapter case VW/Audi passenger vehicle set - VAS

6338/1- ).

10 - Condenser

❑ If there is a receiver with dryer cartridge installed on the condenser, the dryer cartridge must be removed

(seal receiver again on or in condenser following removal) ⇒ Heating, air conditioning .

❑ If the receiver is attached directly to the condenser, remove the receiver after purging and renew ⇒

Heating, air conditioning .

11 - Connection for high-pressure side on refrigerant circuit

❑ Different versions depending on vehicle ⇒ page 86 .

12 - Adapter to connection for high-pressure side on refrigerant circuit

❑ Different versions depending on vehicle ⇒ page 86 .

❑ From adapter case VW/Audi passenger vehicle set - VAS 6338/1- .

13 - Charging hose of flushing device for refrigerant circuits

❑ From connection to high pressure side of air conditioner compressor on refrigerant circuit (smaller di‐

ameter) to inlet of purging device for refrigerant circuits.

14 - Purging device for refrigerant circuits

lk

❑ Different versions and different design e.g. purging device for refrigerant circuits - VAS 6336/1- or purging

device for refrigerant circuits - VAS 6337/1- .

❑ With filter, sight glass, safety valve, heating, refrigerant tank, etc. (depending on version).

❑ Depending on the design of the air conditioner service station and the purging device for refrigerant

circuits, there may be a non-return valve installed at the outlet of the purging device for refrigerant circuits

(to assure the correct direction of refrigerant flow during purging).

15 - Refrigerant hose of air conditioner service station

❑ From the low-pressure side of the air conditioner service station (normally coloured blue) to the outlet of

the purging device for refrigerant circuits

16 - Adapter to seal outlet to second evaporator

❑ Only required on certain vehicles with “second evaporator” (optional equipment).

❑ From adapter case commercial vehicle set - VAS 6338/50- .

17 - Adapter to seal outlet to second evaporator

❑ Only required on certain vehicles with “second evaporator” (optional equipment).

❑ From adapter case commercial vehicle set - VAS 6338/50- .

18 - Connection of low-pressure side on refrigerant circuit to second evaporator

❑ Different versions depending on vehicle ⇒ page 86 .

❑ Only fitted on certain vehicles with “second evaporator” (optional equipment).

19 - Connection of high-pressure side on refrigerant circuit to second evaporator

❑ Different versions depending on vehicle ⇒ page 86 .

❑ Only fitted on certain vehicles with “second evaporator” (optional equipment).

20 - Adapter for removed expansion valve on second evaporator

❑ Different versions depending on vehicle ⇒ page 86 .

❑ Only required on certain vehicles with “second evaporator” (optional equipment).

❑ From adapter case commercial vehicle set - VAS 6338/50- .

21 - Second evaporator

❑ Only fitted on certain vehicles with “second evaporator” (optional equipment).

7. Clearing refrigerant circuit of contaminants

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7.2.2

Purging electrical air conditioner com‐

pressor

Vehicles with high-voltage system

lk

Observe the additional warning instructions for working on vehi‐

cles with high-voltage system ⇒ Electrical system; Rep. gr. 93 ;

General warning instructions for work on the high-voltage sys‐

tem .

WARNING

Risk of injury due to unexpected engine start

When working on a high-voltage vehicle, switch off the ignition,

and deposit the ignition key somewhere outside the passenger

compartment.

WARNING

Handling high-voltage cables:

•

Do not support yourself or your tools on high-voltage ca‐

bles and their components --> risk of damage to the insu‐

lation.

•

High-voltage cables must not be extensively bent or

kinked --> risk of damage to the insulation.

The round high-voltage connectors are colour-coded with

a coloured ring on the outside and mechanically coded

with respective guide lugs. Always observe the coding

when connecting the round high-voltage connectors in or‐

der to prevent any mechanical damage to the high-voltage

connectors.

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DANGER!

Hazardous voltage resulting from damaged high-voltage com‐

ponents

Observe the following when working in the vicinity of high-volt‐

age components and cables:

♦ Work involving metal-removing, deforming and sharp-

edged tools or heat sources such as welding, soldering,

hot air and thermal bonding is not permitted.

♦ Before starting work, carry out a visual check on the high-

voltage components in the area of work.

♦ When working in the engine compartment, carry out a vis‐

ual check on the power and control electronics for electric

drive - JX1- , the electric drive motor - V141- , the air con‐

ditioner compressor - V470- and the high-voltage cables.

lk

♦ When working on the underbody, carry out a visual check

on the high-voltage cables and covers.

♦ When working on the rear end, carry out a visual check on

the high-voltage cables and the maintenance connector

for high-voltage system - TW - .

♦ Carry out a visual check on all potential equalisation lines.

When carrying out the visual check, observe the following:

♦ The high-voltage components must not reveal any exter‐

nal damage.

♦ The insulation of the high-voltage cables and the potential

equalisation lines must not be damaged.

♦ The high-voltage cables must not show any unusual de‐

formations.

♦ Each high-voltage component must be clearly identified

with a red warning sticker.

If repair work in the vicinity of high-voltage components and ca‐

bles is necessary, “carry out a visual check for damage on high-

voltage components and cables”, and “observe the general

warning instructions for work on the high-voltage system” ⇒ Elec‐

trical system; Rep. gr. 93 ; General warning instructions for work

on the high-voltage system .

If repair work on high-voltage components is necessary, de-en‐

ergise the high-voltage system ⇒ Electrical system; Rep. gr. 93 ;

De-energising high-voltage system , and “observe the general

warning instructions for work on the high-voltage system” ⇒ Elec‐

trical system; Rep. gr. 93 ; General warning instructions for work

on the high-voltage system .

Note

The electrical air conditioner compressor must be purged, if you

suspect that there is too much refrigerant oil in the refrigerant cir‐

cuit or if contaminated refrigerant oil (contaminated with moisture)

must be extracted from the air conditioner compressor. In these

cases the refrigerant circuit must be purged as well in order to

clean the refrigerant circuit and to re-establish the correct amount

of refrigerant oil.

If an electrical air conditioner compressor is renewed without hav‐

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

7. Clearing refrigerant circuit of contaminants

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Air conditioning system with refrigerant R134a - Edition 10.2014

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

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

lk

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.

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Air conditioning system with refrigerant R134a - Edition 10.2014

1 - Air conditioner service sta‐

tion

Note

The air conditioner compressor is

purged manually.

–

Extract refrigerant, if

there is any in the sys‐

tem.

Empty the used-oil con‐

tainer of the air condi‐

tioner service station.

Note

Some air conditioner service sta‐

tions first separate the oil in the vac‐

uum phase and then fill it into the

used-oil container.

–

At the air conditioner

service station, set the

amount of refrigerant to

2 kg and the amount of

oil to 0.

Connect purging device

for refrigerant circuits -

VAS 6336/1- or purging

device for refrigerant cir‐

cuits - VAS 6337/1- be‐

tween air conditioner

service station and re‐

turn line for refrigerant

circuit.

lk

–

Evacuate the refrigerant

circuit for 10 minutes. Then observe the vacuum gauge. If the vacuum persists, fill 2 kg of R134a refrig‐

erant into the circuit. Then, extract and evacuate again and repeat the process.

2 - Refrigerant hose of air conditioner service station

❑ From the low-pressure side of the air conditioner service station (normally coloured blue) to the outlet of

the purging device for refrigerant circuits

3 - Purging device for refrigerant circuits

❑ Different versions and different design e.g. purging device for refrigerant circuits - VAS 6336/1- or purging

device for refrigerant circuits - VAS 6337/1- .

❑ With filter, sight glass, safety valve, heating, refrigerant tank, etc. (depending on version).

❑ Depending on the design of the air conditioner service station and the purging device for refrigerant

circuits, there may be a non-return valve installed at the outlet of the purging device for refrigerant circuits

(to assure the correct direction of refrigerant flow during purging).

4 - Charging hose of flushing device for refrigerant circuits

❑ From connection to high-pressure side of air conditioner compressor on refrigerant circuit (smaller di‐

ameter) to inlet of purging device for refrigerant circuits - VAS 6336/1- or purging device for refrigerant

circuits - VAS 6337/1- .

5 - Adapter to connection for high-pressure side on refrigerant circuit

❑ Adapter - VAS 6338/3- from adapter set for refrigerant circuits - VAS 6338/1-

7. Clearing refrigerant circuit of contaminants

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Note

If the adapter - VAS 6338/40- is

available, the charging hose can be

connected directly to the air condi‐

tioner compressor.

6 - High-pressure side refrigerant line from air conditioner compressor

Note

Will not be used if the adapter - VAS

6338/40- is available.

–

Pull the centring pin out of the refrigerant line so that the adapter - VAS 6338/3- fits properly.

7 - Electrical air conditioner compressor

❑ 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 conditioner compressor as possible make sure that

the high-pressure outlet of the air conditioner compressor is in the lowest position possible.

8 - Low-pressure side refrigerant line to air conditioner compressor

Note

Will not be used if the adapter - VAS

6338/41- is available.

–

Pull the centring pin out of the refrigerant line so that the adapter - VAS 6338/6- fits properly.

9 - Adapter to connection for low-pressure side on refrigerant circuit

❑ Adapter - VAS 6338/6- from adapter set for refrigerant circuits - VAS 6338/1-

Note

If the adapter - VAS 6338/41- is

available, the charging hose can be

connected directly to the air condi‐

tioner compressor.

10 - Refrigerant hose of air conditioner service station

❑ From high-pressure side of the air conditioner service station (usually coloured in red) for connection to

low-pressure line or directly to air conditioner compressor using adapter - VAS 6338/41- .

7.2.3

Adapters for setting up purging circuits

♦ The following table contains the various adapters that are nec‐

essary to connect the air conditioner service station to the

refrigerant circuit for purposes of purging and to bridge the re‐

moved reservoir or collector and expansion valve (vehicle-

specific).

♦ Using a filling hose with 5/8 -18 UNF connections (short ver‐

sion, e.g. charging hose - VAS 6338/31- ), join both adapters,

which were installed in place of the reservoir or receiver (in‐

cluded in adapter case VW/Audi passenger vehicle set - VAS

6338/1- ).

♦ If a purged refrigerant circuit is not going to be reassembled

straight after purging, leave the adapters on the connections

and seal the connections at the adapters using the sealing

caps - VAS 6338/30- (from adapter case VW/Audi passenger

vehicle set - VAS 6338/1- ).

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Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

♦ Depending on the type of air conditioner compressor and the

period of production, different joining and sealing techniques

have been applied in the refrigerant circuit ⇒ Heating, air con‐

ditioning .

Block or threaded connections

Threaded connection -A-

Block connection -B-

lk

7. Clearing refrigerant circuit of contaminants

87

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

Air conditioning system with refrigerant R134a - Edition 10.2014

lk

Block connections with various types of seals

Block connection with radial sealing connection -A- (with guide

made from plastic or metal -B-)

– Block connection with axial sealing connection -C-

Fox 2005

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver

conditioner com‐

pressor

Fox

♦ Low-pres‐

sure side

adapter -

VAS

– Remove dryer car‐ – Install

2005 ►

tridge and seal re‐

ceiver.

adapter

- VAS

6338/3

4- in

6338/12-

– After flushing, in‐

stall a new dryer

cartridge.

place of

expan‐

sion

♦ High-pres‐

sure side

adapter -

valve

(or a

VAS 6338/2-

drilled

out ex‐

pan‐

sion

valve

⇒

pa

ge 71 )

– After

purg‐

ing, in‐

stall a

new ex‐

pan‐

sion

valve.

88

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Lupo 1999

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver

conditioner com‐

pressor

Lupo

♦ Low-pres‐

sure side

adapter -

VAS

– Remove receiver

and bridge refriger‐

ant pipes.

– Install

adapter

- VAS

6338/1

9- in

1999 ►

up to ve‐

hicle

♦ Adapter - VAS

6338/28-

identifi‐

cation

number

70000

6338/12-

place of

expan‐

sion

♦ High-pres‐

sure side

♦ Adapter - VAS

6338/29-

adapter -

valve

– After flushing, in‐

stall a new receiver.

VAS 6338/2-

(or dril‐

led out

expan‐

sion

valve

e.g. 6N

0 820

679 C

⇒

pa

ge 71 )

– After

purg‐

lk

ing, in‐

stall a

new ex‐

pan‐

sion

valve.

Lupo

♦ Low-pres‐

sure side

adapter -

VAS

Receiver

– Install

adapter

- VAS

6338/1

9- in

1999 ►

from ve‐

hicle

– Can be flushed

through.

identifi‐

cation

number

70001

6338/12-

– After flushing, in‐

stall a new receiver.

place of

expan‐

sion

♦ High-pres‐

sure side

adapter -

VAS 6338/2-

or

valve

(or dril‐

led out

expan‐

sion

♦ Adapter -

VAS 6338/7-

valve

e.g. 6N

0 820

679 C

⇒

pa

ge 71 )

– After

purg‐

ing, in‐

stall a

new ex‐

pan‐

sion

valve.

7. Clearing refrigerant circuit of contaminants

89

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

Air conditioning system with refrigerant R134a - Edition 10.2014

up! 2012; e-up! 2014

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver

conditioner com‐

lk

pressor

up!

♦ Low-pres‐

sure side

adapter -

VAS

Receiver

– Re‐

2012 ►;

e-up!

– Can be flushed

through.

place

expan‐

sion

2014 ►

6338/12-

– After flushing, in‐

stall a new receiver.

valve

with

♦ High-pres‐

sure side

adapter

- VAS

6338/3

6- or

adapter -

VAS 6338/3-

adapter

- VAS

6338/3

4- (or

drilled-

out ex‐

pan‐

♦ Purging elec‐

trical air con‐

ditioner com‐

pressor,

adapter -

VAS

6338/40- and

Adapter -

VAS

sion

valve

e.g. 1S

0 820

078

6338/41- ,

Observe

notes:

⇒

⇒ page 82

pa

ge 71 ).

– After

purg‐

ing, in‐

stall a

new ex‐

pan‐

sion

valve.

90

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Polo 1995

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver

conditioner com‐

pressor

Polo

Adapter - VAS

– Remove receiver

and bridge refriger‐

ant pipes.

– Install

adapt‐

er -

1995 ► 6338/14-

up to ve‐

hicle

♦ Adapter - VAS

6338/28-

VAS

identifi‐

6338/1

9- in

cation

♦ Adapter - VAS

6338/29-

number

50000

place

of ex‐

pan‐

– After flushing, in‐

stall a new receiver.

sion

valve

lk

(or dril‐

led out

expan‐

sion

valve

e.g. 6N

0 820

679 C

⇒ page

71 )

– After

purg‐

ing, in‐

stall a

new

expan‐

sion

valve.

Polo

♦ Low-pres‐

Receiver

– Install

adapt‐

er -

1995 ►

from ve‐

hicle

sure side

– Can be flushed

through.

adapter -

VAS 6338/7-

VAS

identifi‐

cation

number

50001

– After flushing, in‐

stall a new receiver.

6338/1

9- in

♦ High-pres‐

sure side

place

of ex‐

pan‐

adapter -

VAS 6338/2-

sion

valve

(or dril‐

led out

expan‐

sion

valve

e.g. 6N

0 820

679 C

⇒ page

71 )

– After

purg‐

ing, in‐

stall a

new

expan‐

sion

valve.

7. Clearing refrigerant circuit of contaminants

91

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Polo 2002

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver

conditioner com‐

pressor

Polo

♦ Low-pres‐

sure side

adapter -

VAS

– Remove dryer car‐ – Install

2002 ►

tridge and seal re‐

ceiver.

adapt‐

er -

VAS

lk

6338/12-

– After flushing, in‐

stall a new dryer

cartridge.

6338/3

4- in

♦ High-pres‐

sure side

place

of ex‐

pan‐

adapter -

VAS 6338/2-

sion

valve

(or a

drilled

out ex‐

pan‐

sion

valve

⇒ page

71 )

– After

purg‐

ing, in‐

stall a

new

expan‐

sion

valve.

92

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

Caddy 1996; Caddy 2004; Caddy 2011

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver

conditioner com‐

pressor

Caddy ♦ Low-pres‐

– Remove receiver

and bridge refriger‐

ant pipes.

– Install

1996 ►

sure side

adapter -

adapt‐

er -

VAS 6338/4- ♦ Adapter - VAS

VAS

6338/28-

6338/1

9- in

♦ High-pres‐

sure side

adapter -

VAS 6338/2-

or adapter -

VAS

♦ Adapter - VAS

6338/29-

place

of ex‐

pan‐

– After flushing, in‐

stall a new receiver.

sion

valve

(or dril‐

led out

expan‐

sion

6338/14-

valve

e.g. 6N

0 820

679 C

⇒ page

71 )

– After

purg‐

ing, in‐

stall a

new

expan‐

sion

valve.

Caddy ♦ Sanden /

Receiver

– Install

adapt‐

er -

2004 ►;

Caddy

2011 ►

Denso air

– Can be flushed

through.

conditioner

compressor

VAS

– After flushing, in‐

stall a new receiver.

6338/1

8- in

♦ Low-pres‐

sure side

adapter -

VAS

place

of ex‐

pan‐

6338/12-

sion

valve

(or a

♦ High-pres‐

sure side

drilled

out ex‐

pan‐

adapter -

VAS 6338/3-

sion

♦ 7H0 820 803

D air condi‐

tioner com‐

pressor

valve

⇒ page

71 )

♦ Low-pres‐

sure side

– After

purg‐

adapter -

ing, in‐

stall a

new

VAS 6338/7-

♦ High-pres‐

sure side

expan‐

sion

adapter -

valve.

VAS 6338/2-

7. Clearing refrigerant circuit of contaminants

93

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Polo 2010; Polo KH IN 2010; Polo KH IN 2015; Polo Lim IN 2011;

Polo Lim RUS 2011; Polo KH MY 2014; Polo KH MY 2015; Polo

Lim MY 2014; Polo 2014

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver

conditioner com‐

pressor

Polo

♦ Low-pres‐

sure side

adapter -

VAS

– Remove dryer car‐ – Install

2010 ►;

Polo KH

IN 2010

►; Polo

HH IN

2015;

tridge and seal re‐

ceiver.

adapt‐

er -

VAS

6338/12-

– After flushing, in‐

stall a new dryer

cartridge.

6338/3

4- in

♦ High-pres‐

sure side

place

of ex‐

pan‐

Polo

adapter -

Lim IN

2011 ►;

Polo

VAS 6338/3-

sion

valve

(or a

♦ For air condi‐

tioner com‐

Lim

lk

RUS

drilled

out ex‐

pan‐

pressors 6Q0

820 808 F

2011 ►;

Polo KH

MY

and 6Q0 820

808 G on high

pressure side

adapter -

sion

2014 ►;

Polo KH

MY

valve

⇒ page

71 )

VAS 6338/2-

2015 ►;

Polo

– After

Lim MY

2014 ►;

Polo

purg‐

ing, in‐

stall a

new

2014 ►

expan‐

sion

valve.

94

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Golf 1992; Vento 1992; Passat 1994

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver

conditioner com‐

pressor

Golf

Adapter - VAS

– Remove receiver

and bridge refriger‐

ant pipes.

– Install

adapter

- VAS

6338/1

9- in

1992 ►, 6338/14-

Vento

1992 ►,

♦ Adapter - VAS

6338/28-

Passat

1994 ►

place of

expan‐

sion

♦ Adapter - VAS

6338/29-

valve

– After flushing, in‐

stall a new receiver.

(or dril‐

led out

expan‐

sion

valve

e.g. 6N

0 820

679 C

⇒

pa

ge 71 )

– After

purg‐

ing, in‐

stall a

new ex‐

pan‐

sion

valve.

lk

7. Clearing refrigerant circuit of contaminants

95

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Touran 2003; Golf 2004; Golf Plus 2005; Golf Plus 2009; Jetta

2005; Eos 2006; Golf Variant 2007; Tiguan 2008; Scirocco 2009;

Scirocco 2015; Golf 2009; Golf Variant 2010; Jetta 2011; Golf

Cabrio 2012; NMS 2012; Beetle 2012; Golf 2013

Vehicle Adapters re‐

Adapters required for Miscella‐

lk

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver

conditioner com‐

pressor

Touran ♦ Low-pres‐

There are two versions – Install

2003 ►;

Golf

sure side

adapter -

VAS

of the fluid receiver:

See vehicle specific re‐

pair manual.

adapter

- VAS

6338/1

8- in

2004 ►;

Golf

6338/12-

♦ Fluid receiver with

permanently fitted

dryer

Plus

place of

expan‐

sion

♦ High-pres‐

sure side

2005 ►;

Golf

adapter -

– Can be flushed

through.

Plus

valve

(or a

VAS 6338/3-

2009 ►;

Jetta

– After flushing, in‐

stall a new receiver.

♦ Receiver with dryer

bag or cartridge

drilled

out ex‐

pan‐

2005 ►;

Eos

2006 ►;

Golf

sion

valve

⇒

– Remove dryer bag/

cartridge and seal

fluid receiver.

Variant

2007 ►;

Tiguan

2008 ►;

Sciroc‐

co 2009

►; Scir‐

occo

pa

ge 71 )

– After purging, in‐

stall a new dryer

bag/cartridge.

– After

purg‐

ing, in‐

stall a

new ex‐

pan‐

2015 ►;

Golf

2009 ►;

Golf

sion

valve.

Variant

2010 ►;

Jetta

2011 ►;

Golf

Cabrio

2012 ►;

NMS

2012

►Beetle

2012 ►

96

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Golf 2013; Golf Estate 2014; Golf 2014 (NAR); Golf SV 2015

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver

conditioner com‐

lk

pressor

Golf

♦ Low-pres‐

sure side

adapter -

VAS

– Remove dryer bag/ – Install

2013 ►;

Golf Es‐

tate

cartridge and seal

fluid receiver.

adapter

- VAS

6338/3

8- in

2014 ►;

Golf

6338/12-

– After purging, in‐

stall a new dryer

bag/cartridge.

place of

expan‐

sion

♦ High-pres‐

sure side

2014

(NAR)

►; Golf

SV 2015

►

adapter -

– If a Showa con‐

denser is fitted,

valve

(or a

VAS 6338/3-

leave the receiver

fitted and purge the

refrigerant circuit.

drilled

out ex‐

pan‐

sion

– After flushing, in‐

stall a new receiver.

valve

⇒

pa

ge 71 )

– After

purg‐

ing, in‐

stall a

new ex‐

pan‐

sion

valve.

Golf 1998; Golf Variant 1998; Vento 1999; New Beetle 1999; New

Beetle Cabrio 2003; Bora 1999

Golf

♦ Low-pres‐

sure side

– Remove receiver

and bridge refriger‐

ant pipes.

– Install

adapter

- VAS

6338/1

9- in

1998 ►,

Golf

adapter -

Variant

1998 ►,

Vento

1999 ►,

New

VAS 6338/7-

– Connect two adapt‐

ers - VAS 6338/2-

with hose - VAS

♦ High-pres‐

sure side

place of

expan‐

sion

adapter -

6338/31- together.

VAS 6338/2-

Beetle

1999 ►,

New

valve

(or a

– After flushing, in‐

stall a new receiver.

drilled

out ex‐

pan‐

Beetle

Cabrio

2003 ►,

Bora

sion

valve

⇒

1999 ►

pa

ge 71 )

– After

purg‐

ing, in‐

stall a

new ex‐

pan‐

sion

valve.

7. Clearing refrigerant circuit of contaminants

97

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Phaeton 2003

Vehicle Adapters re‐

lk

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver/reservoir

conditioner com‐

pressor

Phaeton ♦ Low-pres‐

– Remove reservoir – Restric‐

2003 ►

sure side

adapter -

VAS

(dryer), and bridge

refrigerant pipes.

tor re‐

moved

and re‐

friger‐

6338/12-

– Join two adapters -

VAS 6338/6- and

connect to hose -

VAS 6338/31- .

ant pipe

recon‐

nected.

♦ High-pres‐

sure side, 12,

8 and 6-cyl.

petrol en‐

– After flushing, in‐

stall a new reser‐

voir.

– After

gines: adapt‐

er - VAS

flush‐

ing, in‐

stall a

6338/2- .

High-pres‐

sure side, 10

and 6-

new re‐

strictor.

cyl. diesel en‐

gines: adapt‐

er - VAS

6338/3-

98

Rep. gr.00 - Technical data

lk

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Passat 1997

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver/reservoir

conditioner com‐

pressor

Passat ♦ Adapter -

There are two versions – Restric‐

1997 ►

up to

V.A.G

of the reservoir.

– Remove reservoir

and bridge refriger‐

ant pipes.

tor re‐

1785/7-

moved

and re‐

friger‐

Sep‐

♦ Adapter -

V.A.G

tember

2000

ant line

recon‐

nected.

1785/8-

– Connect adapter -

VAS 6338/9- and

adapter - VAG

♦ Low-pres‐

sure side

adapter -

VAS

1785/8- or adapter - – After

VAS 6338/10- to

hose - VAS

flush‐

ing, in‐

stall a

6338/12-

6338/31- .

new re‐

strictor.

♦ High-pres‐

sure side

– After flushing, in‐

stall a new reser‐

voir.

adapter -

VAS 6338/2-

Passat ♦ Adapter -

– Remove reservoir – Restric‐

1997 ►

from

V.A.G

and bridge refriger‐

ant pipes.

tor re‐

1785/7-

moved

and re‐

friger‐

October

2000

♦ Adapter -

V.A.G

– Connect two adapt‐

ers - VAS 6338/10-

with hose - VAS

ant line

recon‐

nected.

1785/8-

6338/31- together.

♦ Low-pres‐

sure side

adapter -

VAS

– After flushing, in‐

stall a new reser‐

voir.

– After

flush‐

ing, in‐

stall a

6338/12-

new re‐

strictor.

♦ High-pres‐

sure side

adapter -

VAS 6338/2-

7. Clearing refrigerant circuit of contaminants

99

lk

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Passat 2006; Passat CC 2009; CC 2010; Passat 2011; CC FL

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver/reservoir

conditioner com‐

pressor

Passat ♦ Low-pres‐

– Remove dryer car‐ – Install

2006 ►,

Passat

CC

sure side

adapter -

VAS

tridge and seal re‐

ceiver.

adapter

- VAS

6338/1

8- in

2009 ►,

CC

6338/12-

– After flushing, in‐

stall a new dryer

cartridge.

place of

expan‐

sion

♦ High-pres‐

sure side

2010 ►,

Passat

2011 ►,

CC FL ►

adapter -

– If a Showa con‐

denser is fitted,

valve

(or a

VAS 6338/3-

leave the receiver

fitted and purge the

refrigerant circuit.

drilled

out ex‐

pan‐

sion

– After flushing, in‐

stall a new receiver.

valve

⇒

pa

ge 71 )

– After

purg‐

ing, in‐

stall a

new ex‐

pan‐

sion

valve.

Passat 2015; Passat Estate 2015

Note

In the Passat 2015 and Passat Estate 2015 with BiTurbo engine,

the refrigerant circuit is not flushed. In these vehicles, it would

require too much effort to remove the expansion valve. If the air

conditioner compressor is defective, check whether filings have

entered the condenser or whether there are filings at the con‐

denser outlet. If there are only filings on the inlet side but not on

the outlet side, renew only the condenser and the air conditioner

compressor.

100

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

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver

conditioner com‐

pressor

Passat ♦ Low-pres‐

– Remove desiccant – Install

2015 ►;

Passat

Estate

2015 ►

sure side

adapter -

VAS

bag/cartridge and

seal fluid receiver.

adapter

- VAS

6338/1

8- in

6338/12-

– After purging, in‐

stall a new desic‐

cant bag/cartridge.

place of

expan‐

sion

♦ High-pres‐

sure side

adapter -

valve

(or a

VAS 6338/3-

drilled

out ex‐

pan‐

sion

valve

⇒

pa

ge 71 )

– After

purg‐

ing, in‐

stall a

new ex‐

pan‐

sion

valve.

Sharan 1996

Note

On vehicles with a 2nd evaporator (Sharan), the front and rear

refrigerant circuit must be rinsed separately. The front refrigerant

circuit must be sealed with adapter - V.A.G 1785/1- , adapter -

1785/3- and sealing caps -VAS 6338/30-.

7. Clearing refrigerant circuit of contaminants

101

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver and 2nd evapo‐

conditioner com‐ rator

pressor

Sharan ♦ Low-pressure – Remove receiver

– Install

adapt‐

er -

1996 ►

up to

May

side adapter -

VAS 6338/7-

and connect refrig‐

erant pipes to

adapter - VAS

VAS

♦ High-pressure

side adapter -

VAS 6338/2-

2000

6338/37- .

6338/3

5- in

– After purging, in‐

stall a new receiver

(dryer).

place

of front

and

♦ or adapter -

VAS 6338/14-

♦ Low-pressure line

for second evapo‐

rator adapter -

rear

expan‐

sion

V.A.G 1785/7-

valves

(or a

♦ High-pressure line

for second eva^lp^ko‐

rator adapter -

drilled

out ex‐

pan‐

V.A.G 1785/5-

sion

♦ Adapter - V.A.G

1785/3- with seal‐

ing cap -VAS

valve

⇒ page

71 )

6338/30- to seal

front refrigerant cir‐

cuit.

– After

purg‐

ing, in‐

stall a

new

♦ Adapter - V.A.G

1785/1- with seal‐

ing cap -VAS

expan‐

sion

6338/30- to seal

front refrigerant cir‐

cuit.

valve.

Sharan ♦ Low-pressure – Remove dryer car‐ – Install

1996 ►

from

side adapter -

VAS 6338/7-

tridge and seal re‐

ceiver.

adapt‐

er -

June

2000

– After flushing, in‐

stall a new dryer

cartridge.

VAS

♦ High-pressure

side adapter -

VAS 6338/2-

6338/3

5- in

♦ Low-pressure line

for second evapo‐

rator adapter -

place

of front

and

V.A.G 1785/7-

rear

expan‐

sion

♦ High-pressure line

for second evapo‐

rator adapter -

valves

(or a

V.A.G 1785/5-

drilled

out ex‐

pan‐

♦ Adapter - V.A.G

1785/3- with seal‐

ing cap -VAS

sion

valve

⇒ page

71 )

6338/30- to seal

front refrigerant cir‐

cuit.

– After

♦ Adapter - V.A.G

1785/1- with seal‐

ing cap -VAS

purg‐

ing, in‐

stall a

new

6338/30- to seal

front refrigerant cir‐

cuit.

expan‐

sion

valve.

102

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Sharan 2011

Note

On vehicles with a 2nd evaporator (Sharan), the front and rear

refrigerant circuit must be rinsed separately. The front refrigerant

circuit must be sealed with adapter - V.A.G 1785/1- , adapter -

1785/3- and sealing caps -VAS 6338/30-.

lk

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver and 2nd evapo‐

conditioner com‐ rator

pressor

Sharan ♦ Low-pressure – Remove dryer car‐ – Install

2011 ►

side adapter -

VAS 6338/12-

tridge and seal re‐

ceiver.

adapt‐

er -

– After flushing, in‐

stall a new dryer

cartridge.

VAS

♦ High-pressure

side adapter -

VAS 6338/3-

6338/1

8- in

♦ Low-pressure line

for second evapo‐

rator adapter - VAS

6338/3-

place

of front

expan‐

sion

valve

(or a

♦ High-pressure line

for 2nd evaporator

adapter - VAS

6338/4-

drilled

out ex‐

pan‐

sion

♦ The refrigerant

lines to the second

evaporator must be

loosened sufficient‐

ly so that the adapt‐

er can be fitted

without deforming

the refrigerant

valve

⇒ page

71 )

– Install

adapt‐

er -

VAS

lines.

6338/3

3- in

♦ Sealing adapter -

VAS 6338/5- for

front refrigerant cir‐

cuit.

place

of rear

expan‐

sion

♦ Sealing adapter -

VAS 6338/11- for

front refrigerant cir‐

cuit.

valve

(or a

drilled

out ex‐

pan‐

sion

valve

⇒ page

71 )

– After

purg‐

ing, in‐

stall a

new

expan‐

sion

valve.

7. Clearing refrigerant circuit of contaminants

103

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Touareg 2003; Touareg 2010; Touareg 2015; Touareg Hybrid

2010

Note

On vehicles with a second evaporator (Touareg), the front and

rear refrigerant circuit must be purged separately. The front re‐

frigerant circuit must be sealed with sealing adapter - VAS

6338/5- and sealing adapter - VAS 6338/11- .

lk

104

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver and second

conditioner com‐ evaporator

pressor

Touar‐ ♦ Low-pressure – Remove dryer car‐ – Install

eg

side adapter -

VAS 6338/12-

tridge and seal re‐

ceiver.

adapt‐

er -

2003 ►

to vehi‐

cle

– After flushing, in‐

stall a new dryer

cartridge.

VAS

♦ High-pressure

side adapter -

VAS 6338/2-

6338/1

7- in

identifi‐

cation

number

50000

♦ Low-pressure line

for second evapo‐

place

of front

expan‐

sion

♦ Engine code

BJN 6.0 l to

lk

rator adapter - VAS

6338/3-

vehicle identi‐

fication num‐

ber 20000 on

high-pressure

side adapter -

VAS 6338/3-

valve

(or a

♦ High-pressure line

for second evapo‐

rator adapter - VAS

6338/4-

drilled

out ex‐

pan‐

sion

♦ Sealing adapter -

VAS 6338/5- for

front refrigerant cir‐

cuit.

valve

⇒ page

71 )

– After

♦ Sealing adapter -

VAS 6338/11- for

front refrigerant cir‐

cuit.

purg‐

ing, in‐

stall a

new

expan‐

sion

valve.

– Drill

out ex‐

pan‐

sion

valve

at sec‐

ond

evapo‐

rator

⇒ page

71 .

– After

purg‐

ing, in‐

stall a

new

expan‐

sion

valve.

7. Clearing refrigerant circuit of contaminants

105

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

Air conditioning system with refrigerant R134a - Edition 10.2014

lk

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver and second

conditioner com‐ evaporator

pressor

Touar‐ ♦ Low-pressure – Remove dryer car‐ – Install

eg

side adapter -

VAS 6338/12-

tridge and seal re‐

ceiver.

adapt‐

er -

2003 ►

as of

– After flushing, in‐

stall a new dryer

cartridge.

VAS

♦ High-pressure

side adapter -

VAS 6338/2-

or adapter -

vehicle

identifi‐

cation

number

50001;

Touar‐

eg

6338/1

7- or

♦ Low-pressure line

for second evapo‐

rator adapter - VAS

6338/3-

adapt‐

er -

VAS 6338/3-

VAS

6338/3

3- in

♦ Electrical air

conditioner

♦ High-pressure line

for second evapo‐

rator adapter - VAS

6338/4-

2010 ►;

Touar‐

eg

place

of front

and

compressor,

adapter - VAS

6338/40- and

adapter - VAS

6338/41-

2015;

Touar‐

eg Hy‐

brid

rear

expan‐

sion

♦ Sealing adapter -

VAS 6338/5- for

front refrigerant cir‐

cuit.

valves

(or a

2010 ►

drilled

out ex‐

pan‐

♦ Sealing adapter -

VAS 6338/11- for

front refrigerant cir‐

cuit.

sion

valve

⇒ page

71 )

– After

purg‐

ing, in‐

stall

new

expan‐

sion

valves.

Transporter 1991

Note

On vehicles with a second evaporator, the front and rear refrig‐

erant circuit must be purged separately. The front refrigerant

circuit must be sealed with sealing adapter - VAS 6338/5- and

sealing adapter - VAS 6338/11- .

106

Rep. gr.00 - Technical data

lk

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver and second

conditioner com‐ evaporator

pressor

Trans‐ ♦ Air condition‐ • If the receiver is at‐ – Install

porter

1991 ►

to

er compres‐

sor 2D0 820

805 B and

701 820 805

Q adapter -

VAS

tached beneath the

condenser, it can

be purged.

adapt‐

er -

VAS

12.1995

6338/5

5- in

– For other versions,

remove reservoir.

♦ Adapter - VAS

6338/20- for receiv‐

er.

place

of front

and

6338/54-

♦ Vehicle with a

additional

evaporator

on the roof,

use adapter -

VAS

rear

expan‐

sion

♦ Adapter - VAS

6338/29- for receiv‐

er.

valves

(or a

drilled

out ex‐

pan‐

♦ Adapter - VAS

6338/26- with seal‐

ing cap -VAS

6338/51- and

adapter -

VAS

sion

6338/30- to seal

front refrigerant cir‐

cuit.

6338/52- .

valve

⇒ page

71 )

♦ Adapter - VAS

6338/27- with seal‐

ing cap -VAS

– After

purg‐

ing, in‐

stall a

new

6338/30- to seal

front refrigerant cir‐

cuit.

expan‐

sion

♦ Adapter - VAS

6338/57- for refrig‐

erant line of second

evaporator.

valve.

♦ Adapter - VAS

6338/58- for refrig‐

erant line of second

evaporator.

– After flushing, in‐

stall a new receiver.

7. Clearing refrigerant circuit of contaminants

107

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver and second

conditioner com‐ evaporator

pressor

Trans‐ ♦ Air condition‐ • If the receiver is at‐ – Install

porter

1991 ►

from

er compres‐

sor 7D0 820

805 E adapt‐

er - VAS

tached beneath the

condenser, it can

be purged.

adapt‐

er -

VAS

Jan.

6338/5

5- in

– For other versions,

remove reservoir.

1996

6338/53-

place

of front

and

♦ Air condition‐ ♦ Adapter - VAS

er compres‐

sor 7D0 820

805 H low-

pressure side

adapter -

6338/20- for receiv‐

er.

rear

expan‐

sion

♦ Adapter - VAS

6338/29- for receiv‐

er.

valves

(or a

VAS 6338/7-

drilled

out ex‐

pan‐

♦ Adapter - VAS

6338/26- with seal‐

ing cap -VAS

♦ High-pres‐

sure side

adapter -

sion

6338/30- to seal

front refrigerant cir‐

cuit.

VAS 6338/2-

valve

⇒ page

71 )

♦ Vehicle with a

additional

evaporator

on the roof,

use adapter -

VAS

♦ Adapter - VAS

6338/27- with seal‐

ing cap -VAS

– After

purg‐

ing, in‐

stall a

new

lk

6338/30- to seal

front refrigerant cir‐

cuit.

6338/51- and

adapter -

expan‐

sion

VAS

♦ Adapter - VAS

6338/57- for refrig‐

erant line of second

evaporator.

6338/52- .

valve.

♦ Adapter - VAS

6338/58- for refrig‐

erant line of second

evaporator.

– After flushing, in‐

stall a new receiver.

Transporter 2004

Note

On vehicles with a second evaporator, the front and rear refrig‐

erant circuit must be purged separately. The front refrigerant

circuit must be sealed with sealing adapter - VAS 6338/5- and

sealing adapter - VAS 6338/11- .

108

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver and second

conditioner com‐ evaporator

pressor

Trans‐ ♦ Air condition‐ – Remove dryer car‐ – To ve‐

porter

7H 2004

►

er compres‐

sor 7H0 820

805 E low-

pressure side

adapter -

tridge and seal re‐

ceiver.

hicle

identi‐

fica‐

tion

– After flushing, in‐

stall a new dryer

cartridge.

num‐

ber

lk

VAS

♦ Sealing adapter -

VAS 6338/5- for

front refrigerant cir‐

cuit.

6338/12- ,

high-pres‐

sure side

20000

, drill

out

adapter -

ex‐

♦ Sealing adapter -

VAS 6338/11- for

front refrigerant cir‐

cuit.

VAS 6338/3-

pan‐

sion

valve

⇒

♦ Air condition‐

er compres‐

sor 7H0 820

803 C low-

pressure side

adapter -

page

71

♦ Low-pressure line

for second evapo‐

rator adapter - VAS

6338/3-

– From

vehi‐

cle

VAS 6338/7- ,

high-pres‐

♦ High-pressure line

for second evapo‐

rator adapter - VAS

6338/4-

sure side

identi‐

fica‐

tion

adapter -

VAS 6338/2-

num‐

ber

20001

, in‐

stall

adapt‐

er -

VAS

6338/

56- in

place

of

front

ex‐

pan‐

sion

valve

– After

purg‐

ing, in‐

stall a

new

ex‐

pan‐

sion

valve.

– Install

adapt‐

er -

VAS

6338/

33- in

place

of ex‐

pan‐

sion

valve

on

7. Clearing refrigerant circuit of contaminants

109

lk

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver and second

conditioner com‐ evaporator

pressor

sec‐

ond

evap‐

orator

– After

purg‐

ing, in‐

stall a

new

ex‐

pan‐

sion

valve.

110

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver and second

conditioner com‐ evaporator

pressor

Trans‐ ♦ Air condition‐ – Remove dryer car‐ – To ve‐

porter

7J 2004

►

er compres‐

sor 7H0 820

805 E low-

pressure side

adapter -

tridge and seal re‐

ceiver.

hicle

identi‐

fica‐

tion

– After flushing, in‐

stall a new dryer

cartridge.

num‐

ber

VAS

♦ Sealing adapter -

VAS 6338/5- for

front refrigerant cir‐

cuit.

6338/12- ,

high-pres‐

sure side

5000,

drill

out

adapter -

ex‐

♦ Sealing adapter -

VAS 6338/11- for

front refrigerant cir‐

cuit.

VAS 6338/3-

pan‐

sion

valve

⇒

♦ Air condition‐

er compres‐

sor 7H0 820

803 C low-

pressure side

adapter -

page

71

♦ Low-pre_ls_ksure line

for second evapo‐

rator adapter - VAS

6338/3-

– From

vehi‐

cle

VAS 6338/7- ,

high-pres‐

♦ High-pressure line

for second evapo‐

rator adapter - VAS

6338/4-

sure side

identi‐

fica‐

adapter -

VAS 6338/2-

tion

num‐

ber

♦ Air condition‐

er compres‐

sor 7H0 820

805 D low-

pressure side

adapter -

5001,

install

adapt‐

er -

VAS

6338/

56- in

place

of

VAS

6338/52- ,

high-pres‐

sure side

adapter -

front

ex‐

VAS

6338/51-

pan‐

sion

valve

– After

purg‐

ing, in‐

stall a

new

ex‐

pan‐

sion

valve.

– Install

adapt‐

er -

VAS

6338/

56- in

place

of ex‐

pan‐

sion

valve

on

sec‐

7. Clearing refrigerant circuit of contaminants

111

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver and second

conditioner com‐ evaporator

pressor

ond

evap‐

orator

– After

purg‐

ing, in‐

stall a

new

lk

ex‐

pan‐

sion

valve.

Transporter 2010; Multivan 2010; California 2010; Caravelle

2010;

Note

On vehicles with a 2nd evaporator, the front and rear refrigerant

circuit must be rinsed separately. The front refrigerant circuit must

be sealed with sealing adapter - VAS 6338/5- and sealing adapter

- VAS 6338/11- .

112

Rep. gr.00 - Technical data

lk

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver and 2nd evapo‐

conditioner com‐ rator

pressor

Trans‐ ♦ Low-pres‐

– Remove dryer car‐ – Install

porter

sure side

adapter -

VAS

tridge and seal re‐

ceiver.

adapt‐

er -

2010 ►,

Multivan

2010 ►,

Califor‐

nia 2010

►, Cara‐

velle

– After flushing, in‐

stall a new dryer

cartridge.

VAS

6338/

56- in

place

of ex‐

pan‐

sion

6338/12-

♦ High-pres‐

sure side

♦ Sealing adapter -

VAS 6338/5- for

front refrigerant cir‐

cuit.

adapter -

VAS 6338/3-

2010 ►

valve

(or a

drilled

out

♦ Sealing adapter -

VAS 6338/11- for

front refrigerant cir‐

cuit.

ex‐

pan‐

sion

♦ Low-pressure line

for second evapo‐

rator adapter - VAS

6338/3-

valve

⇒

pa

ge 71 )

♦ High-pressure line

for second evapo‐

rator adapter - VAS

6338/4-

– Re‐

move

and

drill

open

ex‐

pan‐

sion

valve

for

rear

evap‐

orator

⇒

pa

ge 71 .

– After

purg‐

ing, in‐

stall a

new

ex‐

pan‐

sion

valve.

Crafter 2006; LT 2 as of 1997

Note

On vehicles with a 2nd evaporator, the front and rear refrigerant

circuit must be rinsed separately. The front refrigerant circuit must

be sealed with sealing adapter - VAS 6338/5- and sealing adapter

- VAS 6338/11- .

7. Clearing refrigerant circuit of contaminants

113

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver and 2nd evapo‐

conditioner com‐ rator

pressor

lk

Crafter ♦ Air condition‐ Receiver

– Drill

out

2006 ►

er compres‐ – Can be flushed

sor 2E0 820

803 A low-

pressure side

adapter -

through.

ex‐

– After flushing, in‐

stall a new receiver.

♦ Sealing adapter -

VAS 6338/5- for

front refrigerant cir‐

cuit.

pan‐

sion

valve

⇒

VAS

6338/12- ,

high-pres‐

sure side

page

71

♦ Sealing adapter -

VAS 6338/11- for

front refrigerant cir‐

cuit.

adapter -

– After

purg‐

ing, in‐

stall a

new

VAS 6338/3-

♦ Air condition‐

er compres‐

sor 2E0 820

805 low-pres‐

sure side

♦ Low-pressure line

for second evapo‐

rator adapter - VAS

6338/3-

ex‐

pan‐

sion

adapter -

valve.

VAS 6338/7- ,

high-pres‐

♦ High-pressure line

for second evapo‐

rator adapter - VAS

6338/4-

sure side

adapter -

VAS 6338/3-

LT 2

– Install

adapt‐

er -

♦ Low-pres‐

sure side

– Remove receiver

and bridge refriger‐

ant pipes.

1997 ►

adapter -

VAS

6338/

56- in

place

of ex‐

pan‐

sion

VAS 6338/7-

– Connect two adapt‐

ers - VAS 6338/29-

with hose - VAS

♦ High-pres‐

sure side

adapter -

6338/31- together.

VAS 6338/2-

– After flushing, in‐

stall a new receiver.

♦ Adapter -

VAS

valve

(or a

drilled

out

6338/20-

ex‐

pan‐

sion

valve

⇒

pa

ge 71 )

– After

purg‐

ing, in‐

stall a

new

ex‐

pan‐

sion

valve.

114

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Amarok 2011

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver

conditioner com‐

pressor

Amarok ♦ Low-pres‐

– Remove dryer car‐ – Install

2011 ►

sure side

adapter -

VAS

tridge and seal re‐

ceiver.

adapt‐

er -

VAS

6338/12-

– After flushing, in‐

stall a new dryer

cartridge.

6338/3

3- in

♦ High-pres‐

sure side

place

of ex‐

pan‐

adapter -

,

VAS 6338/3-

sion

valve

(or a

drilled

out ex‐

pan‐

sion

valve

⇒ page

71 )

lk

7. Clearing refrigerant circuit of contaminants

115

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

Air conditioning system with refrigerant R134a - Edition 10.2014

lk

Golf 2009 blue e-Motion

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver

conditioner com‐

pressor and for

air conditioner

compressor itself

Golf

♦ Low-pres‐

sure side

adapter -

VAS

– Remove dryer car‐ – Install

2009

blue e-

Motion

►

tridge and seal re‐

ceiver.

adapter

- VAS

6338/3

4- in

– After flushing, in‐

stall a new dryer

cartridge.

6338/12-

place of

expan‐

sion

♦ High-pres‐

sure side

♦ Shut-off tap - VAS

6338/42-

adapter -

valve

(or a

VAS 6338/3-

drilled

out ex‐

pan‐

♦ Purging elec‐

trical air con‐

ditioner com‐

pressor,

sion

valve

⇒

adapter -

VAS

pa

6338/40- and

Adapter -

VAS

ge 71 )

– After

6338/41- ,

Observe

purg‐

ing, in‐

stall a

new ex‐

pan‐

notes:

⇒ page 82

sion

valve.

– Re‐

move

refrig‐

erant

shut-off

valve

for

high-

voltage

battery

heat

ex‐

chang‐

er -

N542-

and in‐

stall

shut-off

tap -

VAS

6338/4

2- .

– Re‐

move

refrig‐

erant

shut-off

valve

for

heater

and air

condi‐

116

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver

conditioner com‐

pressor and for

air conditioner

compressor itself

tioner

unit -

N541-

and in‐

stall

shut-off

lk

tap -

VAS

6338/4

2- .

Comply

with

notes

⇒

pa

ge

121 .

– If no

shut-off

tap -

VAS

6338/4

2- is

availa‐

ble, a

voltage

of 12 V

may be

applied

to shut-

off

valves -

N541-

and -

N542-

as an

alterna‐

tive.

7. Clearing refrigerant circuit of contaminants

117

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Air conditioning system with refrigerant R134a - Edition 10.2014

e-Golf 2014 and e-Golf 2014 with heat pump

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver

conditioner com‐

pressor and for

air conditioner

compressor itself

e-Golf

♦ Low-pres‐

sure side

adapter -

VAS

– Remove dryer car‐ – Install

2014 ►

tridge and seal re‐

ceiver.

adapter

- VAS

6338/3

4- in

6338/12-

– After flushing, in‐

stall a new dryer

cartridge.

place of

expan‐

sion

♦ High-pres‐

sure side

adapter -

valve

(or a

VAS 6338/3-

drilled

out ex‐

pan‐

♦ Purging elec‐

trical air con‐

ditioner com‐

pressor,

sion

valve

⇒

adapter -

VAS

pa

6338/40- and

Adapter -

VAS

lk

ge 71 )

– After

6338/41- ,

Observe

purg‐

ing, in‐

stall a

new ex‐

pan‐

notes:

⇒ page 82

sion

valve.

118

Rep. gr.00 - Technical data

lk

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Vehicle Adapters re‐

Adapters required for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver

conditioner com‐

pressor and for

air conditioner

compressor itself

e-Golf

2014 ►

with

♦ Low-pres‐

sure side

adapter -

VAS

– Remove reservoir – Start

(dryer), and bridge

refrigerant pipes.

“Basic

setting”

in ⇒ Ve‐

hicle di‐

agnos‐

tic test‐

er, and

start

heat

pump

6338/12-

– Join two adapters -

VAS 6338/6- and

connect to hose -

VAS 6338/31- .

♦ High-pres‐

sure side

adapter -

VAS 6338/3-

– After flushing, in‐

stall a new reser‐

voir.

the

func‐

♦ Purging elec‐

trical air con‐

ditioner com‐

pressor,

tion

“Charg

e refrig‐

erant

adapter -

VAS

circuit”.

♦ This will

open

6338/40- and

Adapter -

VAS

the

electri‐

cal

6338/41- ,

Observe

valves

in the

notes:

⇒ page 82

refrig‐

erant

circuit.

♦ Leave

vehicle

diag‐

nostic

tester

con‐

nected

to keep

the

valves

open.

7. Clearing refrigerant circuit of contaminants

119

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Air conditioning system with refrigerant R134a - Edition 10.2014

Golf Hybrid 2014

Vehicle Adapters re‐

Adapters requir^l^ked for Miscella‐

quired for refrig‐ refrigerant pipes to re‐ neous

erant pipes to air ceiver

conditioner com‐

pressor and for

air conditioner

compressor itself

Golf Hy‐ ♦ Low-pres‐

There are two versions ♦ Install

brid

sure side

adapter -

VAS

of the fluid receiver:

See vehicle specific re‐

pair manual.

adapter -

2014 ►

VAS

6338/38-

in place of

expan‐

6338/12-

♦ Fluid receiver with

permanently fitted

dryer

♦ High-pres‐

sure side

sion valve

(or a dril‐

led out ex‐

pansion

valve

adapter -

– Can be flushed

through.

VAS 6338/3-

– After flushing, in‐

stall a new receiver.

♦ Receiver with des‐

iccant bag or car‐

tridge

♦ Purging elec‐

trical air con‐

ditioner com‐

pressor,

⇒

page 71 )

♦ Replace

shut-off

valves -

N541-

adapter -

VAS

– Remove desiccant

bag/cartridge and

seal fluid receiver.

6338/40- and

Adapter -

VAS

and -

N542-

6338/41- ,

Observe

– After purging, in‐

stall a new desic‐

cant bag/cartridge.

with two

shut-off

taps -

notes:

⇒ page 82

VAS

6338/42- .

Comply

with notes

⇒

page

121 .

♦ Remove

restrictor

in refriger‐

ant line to

heat ex‐

changer

for high-

voltage

battery,

and drill it

out (see

notes be‐

low)

⇒

page

121 .

120

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Air conditioning system with refrigerant R134a - Edition 10.2014

Note

In the Golf Hybrid 2014, the refrigerant circuit is flushed in 2 cy‐

cles. For the first cycle, the adapter for the shut-off valve -N541-

is open, and the adapter for shut-off valve -N542- is closed. This

will cause the refrigerant circuit with the evaporator in the heater

and air conditioning unit to be flushed. For the second cycle, the

lk

adapter for the shut-off valve -N541- is closed, and the adapter

for shut-off valve -N542- is open. This will cause the refrigerant

circuit with the evaporator in the heat exchanger for high-voltage

battery to be flushed ⇒ Heating, air conditioning; Rep. Gr. 87;

Refrigerant circuit; System overview - refrigerant circuit (repair

manual for the specific vehicle).

Note

♦ The illustration shows a refrigerant line -A- with a permanently

installed restrictor -B- (without strainer). This refrigerant line

must be drilled open with a suitable 5 mm drill bit (remove the

restrictor if it is removable), and it must be cleaned before it is

installed in the purging circuit. Renew the refrigerant line which

has been drilled open after purging has been completed ⇒

Electronic Parts Catalogue .

♦ The diameter of the shown restrictor hole -B- is

approx. 0.7 mm. Depending on the refrigerant line version, this

restrictor is permanently installed or it can be removed. For the

removable version a strainer may be fitted to prevent the re‐

strictor hole from being blocked by suspended particles.

7. Clearing refrigerant circuit of contaminants

121

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Air conditioning system with refrigerant R134a - Edition 10.2014

8

Complaints

8.1

Possible complaints about refrigerant

circuit

Note

lk

♦ The air conditioning system is operating correctly if the air

emerging from the vent on the dashboard is at a temperature

o

of 7 C or less.

♦ Set the Climatronic to: “LO”.

♦ Set the air conditioning system: “AC” on; “max”; “cold”.

8.1.1

Test prerequisites:

•

Self-diagnosis of the air conditioning system with the Vehicle

diagnosis, testing and information system - VAS 5051A- using

“Guided Fault Finding” cannot detect any faults; no switch-off

conditions for the air conditioner compressor are set in the

measured value block (only when the vehicle “air conditioning

system” is fitted with self-diagnosis).

⇒ Rep. gr. 87

8.1.2

Possible complaints

Note

For all complaints marked with a * ⇒ page 127 .

♦ The cooling has failed completely. *

♦ Insufficient cooling at all vehicle speeds and engine speeds.*

♦ No cooling or insufficient cooling after a distance of several

kilometres has been driven. *

♦ The air conditioner compressor, the air conditioning system

magnetic clutch - N25- or the air conditioner compressor reg‐

ulating valve - N280- have been switched off by low-pressure

switch for magnetic clutch - F73- , high-pressure switch for

magnetic clutch - F118- , air conditioning system pressure

switch - F129- or by operating and display unit for Climatronic

air conditioning system - E87- or Climatronic control unit -

J255- because pressure was too high or too low.* *

♦ No fresh air flow, or very much reduced fresh air flow after

driving some distance (evaporator iced up). *

In addition the following complaints may also arise:

The air conditioner compressor is noisy

– Tighten the securing screws for the air conditioner compressor

and the air conditioner compressor bracket using a torque

wrench.

– Check routing of refrigerant pipes; they must not touch other

components and must be installed without tension (adjust if

necessary).

122

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Air conditioning system with refrigerant R134a - Edition 10.2014

Noises (refrigerant hammering) occur immediately after the air

conditioning is switched on and/or in a curve or when the brakes

are applied:

– Discharge refrigerant circuit, evacuate and charge again (too

much refrigerant in circuit).

Note

♦ Excess refrigerant oil in the circuit may also cause this problem

(e.g. if the refrigerant oil level was not checked after the air

lk

conditioner compressor was renewed). In case of this com‐

plaint, the refrigerant circuit must be purged with R134a re‐

frigerant ⇒ page 67 .

♦ The refrigerant must be drained from the air conditioning com‐

pressor. To facilitate this process, turn the air conditioner

compressor over by hand at the poly V-belt pulley or coupling

disc of the magnetic coupling. Then fill refrigerant circuit with

total amount of refrigerant oil (50 g direct into air conditioner

compressor) according to ⇒ vehicle-specific workshop man‐

ual .

Water sprays out of the air vents (dash panel or footwell) although

the air conditioning system otherwise works properly:

– Check that the condensation water drain is properly routed; it

must not be pinched or kinked.

– The condensed water drain valve must not be hindered in its

operation by wax or underbody sealant and must open and

close properly.

– Check the plenum chamber cover; it must be undamaged and

be installed correctly (no water must flow into the evaporator).

– Check water drains in plenum chamber; they must not be

blocked (e.g. by leaves).

8.2

Smells from heater and air conditioner

unit

8.2.1

Is the smell coming from evaporator or

the heat exchanger?

♦ Fishy smell

– Due to leak in engine's cooling system or in heat exchanger of

heater and air conditioner unit.

Note

If the fishy smell is weaker when the temperature is set to “cold”

or stronger when the temperature is set to “warm”, check the heat

exchanger for leaks.

♦ Smell of a burnt clutch

♦ Vapours from foot mats, retrospectively installed seat covers

etc.

♦ Putrid, mouldy smell

– Due to accumulation of leaves, pine needles etc. in plenum

chamber.

8. Complaints

123

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Note

Clean plenum chamber.

lk

– Use water so that it cannot flow out of plenum chamber.

Note

Check water runoff points in plenum chamber.

♦ Smell from heater and air conditioner unit

Note

Smells that can originate in heater and air conditioner unit can be

detected in fresh air mode and in recirculation mode.

– Due to too much condensation water in heater and air condi‐

tioner unit

Note

Check the runoff points of condensation water ⇒ Rep. gr. 87 as

indicated in the vehicle-specific repair manual.

– Due to an old or very dirty dust and pollen filter

Note

Check the dust and pollen filter ⇒ Rep. gr. 80 as indicated in the

vehicle-specific repair manual.

– Due to deposits on the fins of the evaporator

Note

Clean the evaporator, using the ultrasonic air conditioner cleaning

unit - VAS 6189A- ⇒ page 124 or the suction feed spray-gun -

V.A.G 1538- and corresponding spray lance ⇒ page 125 .

8.2.2

Ultrasonic air conditioner cleaning unit -

VAS 6189A-

– The ultrasonic air conditioner cleaning unit - VAS 6189A- must

be placed in the front-passenger footwell and sprays the agent

Aero-Clean. Aero-Clean neutralises microbes and bacteria in

the heater and air conditioner unit.

The device is provided with instructions for use.

Current equipment ⇒ ServiceNet; Workshop Equipment; Cata‐

logue; Workshop equipment; Air conditioning/heating; Service

equipment

124

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Air conditioning system with refrigerant R134a - Edition 10.2014

8.2.3

Spraying the evaporator with the suction

feed spray-gun - V.A.G 1538- and spray

lance

Spray the evaporator with Contra Sept directly using a spray

lance (approx. 10 bar). Contra Sept neutralises microbes and

bacteria directly at the evaporator.

In order to enable access to the evaporator, some preliminary

work and different spray lances are necessary, e.g. V.A.G 1538/5;

V.A.G 1538/6 or V.A.G 1538/7.

Vehicle-specific instructions for user are provided with the evap‐

orator cleaning solution D 600 100 A2.

Current equipment and spray lances ⇒ ServiceNet Function

“Search”

lk

8. Complaints

125

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Air conditioning system with refrigerant R134a - Edition 10.2014

lk

9

Connecting air conditioner service

station

9.1

For vehicles that have connections on

both low-pressure and high-pressure

sides of refrigerant circuit

9.1.1

Connecting air conditioner service sta‐

tion for measuring and checking

– Switch off ignition.

– Connect air conditioner service station to power supply.

– Connect quick-release coupling adapters to charging hoses

for air conditioner service station (handwheels not turned in‐

wards, i.e. hand shut-off valves not open).

– Switch on air conditioner service station and evacuate charg‐

ing hoses (necessary only if there is air in the charging hoses).

– Switch off air conditioner service station.

– Unscrew sealing caps from service connections (with valve).

– Connect air conditioner service station via service connections

to the vehicle refrigerant circuit using quick-release coupling

adapter.

– Turn handwheel of quick-release coupling adapter inwards

only far enough to ensure that valves on service connections

are open (check using a pressure gauge; do not overstress

valves).

– Perform the intended measuring and checking work.

126

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Air conditioning system with refrigerant R134a - Edition 10.2014

10

Checking pressures on vehicles

10.1

Checking pressures in refrigerant circuit

(using air conditioner service station)

lk

Note

♦ Check the cooling performance. The air conditioning system

is operating correctly if the air emerging from the vent on the

o

dashboard is at a temperature of 7 C or less.

♦ Set the Climatronic to: “LO”.

♦ Set the air conditioning system: “AC” on; “max”; “cold”.

♦ Connections with valve and service connections for measuring

and testing.

10.1.1

Test prerequisites

•

Radiator and condenser must be clean (clean them if neces‐

sary).

The heat insulation on expansion valve is OK and properly

installed. See vehicle-specific repair manual ⇒ Rep. gr. 87 .

The poly V-belt is OK and properly tensioned. The V-belt for

air conditioner compressor and alternator is in good condition

and correctly tensioned. See vehicle-specific repair manual ⇒

Rep. gr. 87

•

All air ducts, covers and seals are OK and properly installed.

Fault-finding on the electrical systems and vacuum system

has found no faults. See vehicle-specific repair manual ⇒ Rep.

gr. 87

•

Self-diagnosis of the air conditioning system with the vehicle

diagnosis, testing and information system - VAS 5051A- using

“guided fault finding” cannot detect any faults; no switch-off

conditions for the air conditioner compressor are set in the

measured value block (only when the vehicle “air conditioning

system” is fitted with self-diagnosis).

•

The passage of air through the dust and pollen filter is not im‐

paired by dirt. See vehicle-specific repair manual ⇒ Rep. gr.

87

The heater and air conditioner does not draw any secondary

air at highest fresh air blower speed. The evaporator and heat‐

ing do not draw any uncooled air at highest fresh air blower

speed. See vehicle-specific repair manual ⇒ Rep. gr. 87

•

The air duct flaps in the heater and air conditioner reach their

stop positions. See vehicle-specific repair manual ⇒ Rep. gr.

87

The fresh air intake ducts under the bonnet and in the pas‐

senger compartment and their water drain valves are in good

condition. See vehicle-specific repair manual ⇒ Rep. gr. 87

•

The engine is at operating temperature.

The vehicle is not exposed to direct sunlight.

The ambient temperature is higher than 15°C.

All dash panel air vents are open.

10. Checking pressures on vehicles

127

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Air conditioning system with refrigerant R134a - Edition 10.2014

•

With engine running and air conditioning set for maximum

cooling output:

⇒ Rep. gr. 87

Setting maximum cooling output

Settings on operating and display unit for Climatronic air condi‐

tioning system - E87-

– Select “Auto” mode (air conditioner compressor switched on).

– Select temperature setting “LO” for driver and front passenger.

Settings on heater controls:

– A/C button and Rec or recirculate _lb_kuttons should be pressed.

– Set rotary temperature switch to “Cold” stop.

– Set rotary fresh air blower switch to “4”.

•

The radiator fan(s) should be running radiator fan - V7- (at

least at speed 1).*

Note

In some versions, the fan is not switched on until the pressure in

the refrigerant circuit has exceeded a specified value.

•

The fresh air blower - V2- should be running at maximum

speed.

The air flap for fresh air and air recirculation moves to the “re‐

circulation” position or the air flow flap closes and the recircu‐

lation flap opens (within 1 minute of starting the vehicle).

•

The coolant shut-off valve is closed. *

The valves for the pump valve unit are closed (and the coolant

circulation pump is not pumping).*

10.1.2

Checking pressures

– Switch off ignition.

– Connecting air conditioner service station ⇒ page 126 .

– Read pressure from pressure gauges; two results may be dis‐

played.

Ambient temperature (in de‐ Pressure in the refrigerant cir‐

grees centigrade)

+15℃

cuit in bar positive pressure

3.9

4.7

5.6

6.7

7.8

9.1

10.5

+20 ℃

+25℃

+30 ℃

+35℃

+40 ℃

+45℃

128

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Air conditioning system with refrigerant R134a - Edition 10.2014

Note

♦ The temperature of the components of the refrigerant circuit

should be the same as the ambient temperature.

♦ If individual components of the refrigerant circuit are warmer

or colder, then the pressure will deviate from the values shown

in the tables.

♦ Absolute pressure means that 0 bar corresponds to an abso‐

lute vacuum. The normal ambient pressure (positive pressure)

corresponds to 1 bar absolute pressure. On most pressure

gauges, a reading of 0 bar corresponds to an absolute pres‐

sure of one bar (which is confirmed by the existence of - 1 bar

marking beneath the 0 scale marking).

♦ Where vehicles have a high-pressure sender - G65- which in‐

dicates the measured pressure in_lt_khe measured values block,

the measured pressure should agree with the values in the

tables.

⇒ Rep. gr. 87

The pressure in the refrigerant circuit is lower than indicated in

the table

Insufficient refrigerant in circuit.

– Check for leaks in the refrigerant circuit ⇒ page 58 .

– Check the high-pressure safety valve.

If the high-pressure safety valve has blown off:

– Check activation of radiator fan.

– Check refrigerant pipes and refrigerant hoses for restrictions

in cross-section at bends that have too tight radius.

– Check refrigerant pipes and refrigerant hoses for external

damage.

– If no defects are found, blow through refrigerant circuit with

compressed air and nitrogen.

The pressure in the refrigerant circuit is equal to or greater than

that in the table

– Start engine.

– On vehicles with electrical air conditioner compressor, switch

off ignition.

WARNING

High voltage on high-voltage system of hybrid vehicle. Danger

of electric shock! Before starting work, carry out a visual check

of high-voltage components in area of work. Comply with gen‐

eral warnings ⇒ Hybrid electrical system; Rep. gr. 93 ; General

warnings for working on the high-voltage onboard power sup‐

ply system .

– Set air conditioning system for maximum cooling output.

10. Checking pressures on vehicles

129

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Air conditioning system with refrigerant R134a - Edition 10.2014

Note

If the low-pressure switch had been removed in order to connect

the air conditioner service station, bridge the electrical connec‐

tions in the respective connector for pressure measurement.

•

The air conditioner compressor is driven by the engine via the

air conditioning system magnetic clutch - N25- .

The air conditioner compressor regulating valve - N280- is ac‐

tivated by the Climatronic control unit - J255- .

⇒ Rep. gr. 87

If the air conditioner compressor is not driven or the ^lr^kegulating

valve not activated when the engine is running:

– Determine the cause, e.g. by reading the event memory for

the air conditioning system, and rectify it.

– Observe the test prerequisites.

– Check power supply for air conditioning system magnetic

clutch - N25- . If this is OK, repair magnetic clutch.

– Check actuation of air conditioner compressor regulating valve

- N280- .

⇒ Rep. gr. 87 .

10.1.3

Continuation of checking pressures

♦ Where vehicles have a restrictor and reservoir, check these

(with internally regulated air conditioning system compressor)

⇒ page 130 .

♦ Where vehicles have an expansion valve and receiver, check

these (with internally regulated air conditioner compressor)

⇒ page 135 .

♦ Where vehicles have an expansion valve and receiver, check

these (without internally regulated air conditioner compressor)

⇒ page 141 .

♦ Where vehicles have a restrictor and reservoir and air condi‐

tioning system compressor regulating valve - N280- (external‐

ly regulated air conditioning system compressor)

⇒ page 143 .

10.2

Checking systems with a restrictor and

collector (with internally regulated air

conditioner compressor)

Note

♦ Connecting air conditioner service station ⇒ page 126 .

♦ Observe the test prerequisites ⇒ page 127 .

– Raise engine speed to 2,000 rpm.

– Observe air conditioner service station pressure gauge.

130

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Air conditioning system with refrigerant R134a - Edition 10.2014

Note

♦ Switch pressures for switches in refrigerant circuit are vehicle-

specific.

♦ The connection with a valve for the low-pressure switch or on

the evaporator should only be used where the vehicle does

not have a service connection on the low-pressure side and

access to the connection on the air conditioner compressor or

reservoir is not possible (measurement accuracy). This only

applies to certain vehicles.

⇒ Rep. gr. 87

10.2.1

Specifications:

High-pressure side:

Rising from starting pressure (when pressure gauge is connec‐

ted) to maximum 20 bar.

lk

Low-pressure side:

Falling from starting pressure (when pressure gauge is connec‐

ted) to diagram value.

A - High pressure (measured at the service connection) in bar

positive pressure.

B - Low pressure (measured at the connection with the valve at

the air conditioner compressor or at the reservoir) in bar positive

pressure.

C - Permitted tolerance range.

D - Low pressure (measured at the connection with the valve for

the low-pressure switch or at the service connection) in bar pos‐

itive pressure.

E - Permitted tolerance range.

Possible deviation from specification

Possible cause of fault

Rectifying fault

•

High pressure remains constant or in‐ Insufficient refrigerant in cir‐

creases only slightly (above the pres‐ cuit.

sure measured when the engine is

– Look for leaks and rectify them.

– Recharge refrigerant circuit.

stopped),

•

Low pressure falls quickly to the dia‐

gram value or lower,

The required cooling output is not de‐

livered.

•

High pressure is normal,

Low pressure matches the diagram

value,

•

The required cooling output is not de‐

livered.

10. Checking pressures on vehicles

131

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Air conditioning system with refrigerant R134a - Edition 10.2014

lk

Possible deviation from specification

High pressure is normal,

Possible cause of fault

Rectifying fault

•

Low pressure is too low (see dia‐

gram),

•

The required cooling output is not de‐

livered.

Note

If no fault can be found for this complaint, purge (clean) refrigerant

circuit with refrigerant R134a ⇒ page 67 . If this is not possible in

your workshop, blow through refrigerant circuit with compressed

air and dry with nitrogen ⇒ page 65 .

Possible deviation from specification

Possible cause of fault

Rectifying fault

•

High pressure increases only slightly The air conditioner compressor is de‐ – Purge (clean) refriger‐

above the pressure measured when fective.

the engine is stopped,

ant circuit ⇒ page 67 .

– Renew air conditioner

compressor.

•

Low pressure falls only slightly,

The required cooling output is not

delivered.

Possible deviation from specification

Possible cause of fault

Rectifying fault

•

High pressure rises above specifica‐ Restriction or obstruction in the refrigerant – Feel the refrigerant

tion,

circuit.

circuit with the hand

to sense the tem‐

perature gradient.

Low pressure falls quickly to the di‐

agram value or lower,

•

At one component a

temperature gradi‐

ent will be detected:

The required cooling output is not

delivered.

– If a hose or pipe is

kinked or crushed,

renew it.

– In case of an ob‐

struction, blow

through refrigerant

circuit with com‐

pressed air and ni‐

trogen.

– Repeat the check; if

the system does not

operate correctly

– Purge (clean) refrig‐

erant circuit

⇒ page 67 .

132

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Possible deviation from specification

Possible cause of fault

Rectifying fault

•

High pressure and low pressure are Moisture in the refrigerant circuit.

normal at first, but after a time,

– Blow through refrig‐

erant circuit with

compressed air and

nitrogen.

The high pressure increases beyond

lk

the specified value,

– Renew receiver.

The low pressure falls to the diagram

value or lower,

– Repeat the check; if

the system does not

operate correctly

The cooling power called for is not

delivered.

– Purge (clean) refrig‐

erant circuit

⇒ page 67 .

– Recharge refriger‐

ant circuit.

– Repeat check.

•

High pressure is normal,

The air conditioner compressor is defec‐ – Purge (clean) refrig‐

tive.

erant circuit

⇒ page 67 .

Low pressure is too low (see dia‐

gram),

– Renew air condi‐

tioner compressor.

•

The cooling power required is deliv‐

ered.

Note

♦ If the fault is “high pressure normal, low pressure too low ”

please note the following:

♦ In this case, the evaporator may be iced up or the low-pressure

switch for air conditioning system - F73- has switched off the

air conditioning system compressor, although the correct

quantity of refrigerant is present in the refrigerant circuit.

10. Checking pressures on vehicles

133

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Possible deviation

from specification

Possible cause of fault

Rectifying

fault

•

High pressure nor‐ Too much refrigerant in – Extract

mal or too high,

circuit.

some re‐

frigerant

from the

refriger‐

ant cir‐

cuit.

Low pressure too

high (see dia‐

gram),

•

The air conditioner

compressor is

noisy (especially

immediately after

being switched

on),

•

The

quantity

of refrig‐

erant ex‐

tracted is

about

•

The required cool‐

ing output is not

delivered.

equal to

the pre‐

scribed

charge

quantity.

– Renew

the air

condition‐

er com‐

pressor.

•

The

quantity

of refrig‐

erant ex‐

tracted is

signifi‐

cantly

lk

greater

than the

prescri‐

bed

charge

quantity.

– Recharge

refriger‐

ant cir‐

cuit.

– Repeat

check.

Possible deviation from specification

Possible cause of fault

Rectifying fault

•

High-pressure and low-pressure Too much refrigerant oil in circuit.

– Drain refrigerant cir‐

cuit.

are normal,

•

The required cooling output is not

delivered.

– Purge (clean) refrig‐

erant circuit

⇒ page 67 .

•

High-pressure and low-pressure

are normal,

The air conditioner compressor is

noisy (especially immediately af‐

ter being switched on),

•

The cooling power required is de‐

livered.

134

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

♦ Overfilling with refrigerant oil can occur if the refrigerant oil

level was not checked after the air conditioner compressor

was renewed.

♦ If the air conditioner compressor is not to be replaced, drain

refrigerant oil from air conditioner compressor via the drain

plug. From the total amount of refrigerant oil, fill 50 g direct into

air conditioner compressor and fill remainder in refrigerant cir‐

cuit according to ⇒ vehicle-specific workshop manual .

10.3

Checking systems with an expansion

valve and reservoir (with internally regu‐

lated air conditioner compressor)

Note

♦ Connecting air conditioner service station ⇒ page 126 .

♦ Observe the test prerequisites ⇒ page 127 .

– Raise engine speed to 2,000 rpm.

– Observe manifold gauge.

Note

The switch pressures and the versions of switches in the refrig‐

erant circuit are vehicle-specific.

Pressures must be measured at the service conne^lc^ktions; the fit‐

ting locations of these connections are vehicle-specific.

⇒ Rep. gr. 87

10.3.1

Specifications:

High-pressure side:

Rising from starting pressure (when pressure gauge is connec‐

ted) to maximum 20 bar.

10. Checking pressures on vehicles

135

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Low-pressure side:

Falling from starting pressure (when pressure gauge is connec‐

ted) to diagram value.

A - High pressure in bar positive pressure.

B - Low pressure in bar positive pressure.

C - Permitted tolerance range.

lk

136

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Possible deviation

from specification

Possible cause of fault

Rectifying

fault

•

High pressure re‐ Too little refrigerant in cir‐ – Extract

mains constant or cuit or expansion valve

some re‐

frigerant

from the

refriger‐

ant cir‐

cuit.

increases only

defective.

slightly (above the

pressure meas‐

ured when the en‐

gine is stopped),

•

Low pressure falls

quickly to the dia‐

gram value or low‐

er,

•

The

quantity

of refrig‐

erant ex‐

tracted is

about

The required cool‐

ing output is not

delivered.

equal to

the pre‐

scribed

charge

quantity.

– Renew

expan‐

sion

valve.

– Recharge

refriger‐

ant cir‐

cuit.

– Repeat

check.

•

High pressure is

normal,

•

The

quantity

of refrig‐

erant ex‐

tracted is

signifi‐

Low pressure

matches the dia‐

gram value,

lk

cantly

•

The required cool‐

ing output is not

delivered.

less than

the pre‐

scribed

charge

quantity.

– Look for

leaks us‐

ing leak

detector

and recti‐

fy them.

– Recharge

refriger‐

ant cir‐

cuit.

– Repeat

check.

10. Checking pressures on vehicles

137

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Note

If no fault can be determined and the function of the air condi‐

tioning system is not OK when the test is repeated, purge refrig‐

erant circuit with refrigerant R134a (clean) ⇒ page 67 . If thi_ls_kis

not possible in your workshop, blow through refrigerant circuit with

compressed air and dry with nitrogen ⇒ page 65 .

Possible deviation

from specification

Possible cause of fault

Rectifying

fault

•

High pressure

rises above speci‐

fication,

♦ Restriction or obstruc‐ – Feel the

tion in the refrigerant

circuit.

refriger‐

ant circuit

with the

hand to

sense the

tempera‐

ture gra‐

dient.

Low pressure falls ♦ Expansion valve de‐

quickly to the dia‐

gram value or low‐

er,

fective.

•

The required cool‐

ing output is not

delivered.

•

At one

compo‐

nent a

tempera‐

ture gra‐

dient will

be detec‐

ted:

– If a hose

or pipe is

kinked or

crushed,

renew it.

– In case of

an ob‐

struction,

purge re‐

frigerant

circuit

with com‐

pressed

air and ni‐

trogen

and re‐

new ex‐

pansion

valve.

•

If no

faults are

found:

– Purge

(clean)

refriger‐

ant circuit

⇒

page 67 .

– Repeat

check.

138

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 air conditioning system is still not operating correctly after

the refrigerant circuit has been purged with compressed air and

nitrogen, the expansion valve must be renewed.

lk

Possible deviation from specification

Possible cause of fault

Rectifying fault

•

High pressure and low pressure ♦ Expansion valve defective.

– Examine the expan‐

sion valve for dirt or

corrosion; renew if

necessary.

are normal at first,

♦ Moisture in the refrigerant circuit.

•

After a while, the high pressure

increases beyond the specifica‐

tion, and the low pressure falls to

the diagram value or lower,

– Blow through refrig‐

erant circuit with

compressed air and

nitrogen.

•

The cooling power called for is

not delivered.

– Renew receiver.

– Repeat the check; if

the system does not

operate correctly

– Purge (clean) refrig‐

erant circuit

⇒ page 67 .

– Recharge refriger‐

ant circuit.

– Repeat check.

Note

When this fault occurs, always renew receiver.

10. Checking pressures on vehicles

139

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Possible deviation from specification

Possible cause of fault

Rectifying fault

•

High pressure normal or too high ♦ Too much refrigerant in circuit.

– Extract some refrig‐

erant from the re‐

frigerant circuit.

(see diagram),

♦ Expansion valve or air conditioner com‐

pressor defective.

The required cooling output is not

delivered.

•

The quantity of re‐

frigerant extracted

is about equal to the

prescribed charge

quantity.

The air conditioner compressor is

noisy (especially immediately af‐

ter being switched on),

– Renew expansion

valve.

– Recharge refriger‐

ant circuit.

– Repeat test.

lk

•

The quantity of re‐

frigerant extracted

is significantly

greater than the

prescribed charge

quantity.

– Recharge refriger‐

ant circuit.

– Repeat check.

Note

If the air conditioning system is still not operating correctly when

the test is repeated, refit the expansion valve and purge the re‐

frigerant circuit with compressed air and nitrogen. Then renew the

air conditioner compressor and receiver.

Possible deviation from specification

Possible cause of fault

Rectifying fault

•

High pressure increases only

slightly above the pressure

measured when the engine is

stopped,

♦ The air conditioner compressor is defec‐ – Purge (clean) refrig‐

tive.

erant circuit

⇒ page 67 .

– Renew the air condi‐

tioner compressor

and receiver.

•

Low pressure falls only slightly,

The required cooling power is not

delivered.

Possible deviation

from specification

Possible cause of fault

Rectifying

fault

•

High pressure is ♦ Expansion valve or air – Renew

normal,

conditioner compres‐

sor defective.

expansion

valve.

Low pressure is

too low (see dia‐

gram),

– Recharge

refrigerant

circuit.

•

The cooling pow‐

er required is de‐

livered.

– Repeat

check.

140

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 repeated check results in air conditioning system still not

operating correctly, purge (clean) the refrigerant circuit

⇒ page 67 . Then renew the air conditioner compressor and

receiver.

♦ In this case, the evaporator may ice up although the correct

quantity of refrigerant is present in the refrigerant circuit.

Possible deviation from specification

Possible cause of fault

Rectifying fault

•

High-pressure and low-pressure Too much refrigerant oil in circuit.

are normal,

– Drain refrigerant cir‐

cuit.

•

The required cooling output is not

delivered.

– Purge (clean) refrig‐

erant circuit

⇒ page 67 .

•

High-pressure and low-pressure

are normal,

The air conditioner compressor is

noisy (especially immediately af‐

ter being switched on),

•

The cooling power required is de‐

livered.

Note

♦ Overfilling with refrigerant oil can occur if the refrigerant oil

level was not checked after the air conditioner compressor

was renewed.

♦ If the air conditioner compressor is not to be replaced, drain

refrigerant oil from air conditioner compressor via the drain

plug. From the total amount of refrigerant oil, fill 50 g direct into

air conditioner compressor and fill remainder in refrigerant cir‐

cuit according to ⇒ vehicle-specific workshop manual .

lk

10.4

Checking systems with an expansion

valve and reservoir (without regulated

air conditioner compressor)

10.4.1

Test prerequisites

•

Radiator and condenser must be clean (clean them if neces‐

sary).

•

The V-belt for air conditioner compressor and alternator is

correctly tensioned.

•

All air ducts, covers and seals are OK and properly installed.

The flaps reach their end positions.

The engine is at operating temperature.

The evaporator and heating do not draw any uncooled air at

highest fresh air blower speed.

10. Checking pressures on vehicles

141

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

Air conditioning system with refrigerant R134a - Edition 10.2014

With the engine running and the air conditioning system set to full

power, check the following points:

•

The fresh air blower is running

The radiator fan is running or is switched on.

The fresh air and air recirculation flap is set to “recirculate”.

o

The ambient temperature is more than 15 C.

•

The temperature switch for evaporator - E33- is correctly fitted

and its switching temperatures are correct.

10.4.2

Checking

– Switch off ignition.

– Connect manifold gauge (air conditioner service station).

– Read pressure gauge. It may display two results, A and B.

Ambient temperature in de‐

grees centigrade

Pressure ^li^kn the refrigerant cir‐

cuit in bar positive pressure

+15℃

+20 ℃

+30 ℃

+40 ℃

3.9

4.7

6.7

9.1

♦ A- The pressure in the refrigerant circuit is less than shown in

the table, (insufficient refrigerant in the circuit).

- Check for leaks using leak detector.

- The high-pressure safety valve has opened; check the activation

for the radiator fan referring to the current flow diagram.

Check refrigerant pipes and refrigerant hoses for bends that have

too tight radius (restrictions in cross-section) and for external

damage. If no faults are found, purge the refrigerant circuit.

♦ B- The pressure in the refrigerant circuit is greater than or

equal to the value in the table.

– Start engine.

– Set air conditioning system to maximum cooling power.

– Open doors.

– Open vents in dash panel.

The air conditioner compressor is driven by the engine, via the V-

belt and magnetic clutch.

Note

♦ If the air conditioner compressor is not being driven, check the

power supply for the air conditioning system magnetic clutch

- N25- in accordance with the current flow diagram.

♦ If power supply is OK, repair magnetic clutch.

If the air conditioner compressor is not being driven, check the

refrigerant circuit:

– Raise engine speed to 2,000 rpm.

– Observe the manifold gauge.

142

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

10.4.3

Specifications

High-pressure side:

Increasing from the pressure when the engine is stopped to a

maximum of 20 bar positive pressure.

Low-pressure side:

Decreasing from the pressure when the engine is stopped to 1.3

bar positive pressure.

10.5

Checking systems with a restrictor and

reservoir and air conditioner compres‐

sor regulating valve - N280- (with exter‐

nally regulated air conditioner compres‐

sor)

Note

♦ Connecting air conditioner service station ⇒ page 126 .

lk

♦ Observe the test prerequisites ⇒ page 127 .

– Raise engine speed to 2,000 rpm.

– Observe air conditioner service station pressure gauge.

Note

Switching pressures for the air conditioner compressor regulating

valve - N280- and the radiator fan - V7- are vehicle-specific.

⇒ Rep. gr. 87

10.5.1

Specifications:

High-pressure side:

Rising from starting pressure (when pressure gauge is connec‐

ted) to 20 bar.

10. Checking pressures on vehicles

143

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Low-pressure side:

Falling from starting pressure (when pressure gauge is connec‐

ted) to diagram value.

A - Low pressure (measured at the service connection) in bar ab‐

solute pressure.

B - Control current for the air conditioner compressor regulating

valve - N280- .

C - Permitted tolerance range.

Note

♦ Under unfavourable conditions (very high ambient tempera‐

tures, high atmospheric humidity), the pressure on the high-

pressure side can increase to a maximum of 29 bar.

♦ The control current -B- is indicated in the measured values

block.

♦ The high pressure is indicated in the measured values block

⇒ Rep. gr. 87 .

lk

♦ The low pressure is adjusted to within tolerances within the

output range for the air conditioner compressor depending on

the control current for the air conditioner compressor regulat‐

ing valve - N280- .

♦ Under unfavourable conditions (very high ambient tempera‐

tures, high atmospheric humidity), the output may be insuffi‐

cient to achieve the specification in every case.

♦ The set working current for the regulating valve must be great‐

er than 0.3 A to ensure that the regulating valve is reliably

activated.

♦ At the setting for “maximum cooling power”, the control current

should be approx. 0.8 A (indicated in the measured values

block) ⇒ Rep. gr. 87 .

♦ Absolute pressure means that 0 bar corresponds to an abso‐

lute vacuum. The normal ambient pressure corresponds to 1

bar absolute pressure. On most pressure gauges, a reading

of 0 bar corresponds to an absolute pressure of one bar (which

is confirmed by the existence of - 1 bar marking beneath the

0 scale marking).

144

Rep. gr.00 - Technical data

lk

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Possible deviation Possible cause of fault Rectifying fault

from specification

•

High pressure

remains con‐

♦ Actuation of air con‐ – Check ac‐

ditioner compressor

regulating valve -

N280- is defective.

tuation of air

conditioner

compressor

regulating

valve -

stant or increa‐

ses only slightly

(above the pres‐

sure measured

when the engine

is stopped),

♦ Insufficient refriger‐

ant in circuit.

N280- .

– Look for

•

Low pressure

falls quickly to

the diagram val‐

ue or lower,

leaks using

leak detector

and rectify

them.

The required

– Recharge re‐

frigerant cir‐

cuit.

cooling output is

not delivered.

•

High pressure is

normal,

Low pressure

matches the dia‐

gram value,

•

The required

cooling output is

not delivered.

•

High pressure is

normal,

Low pressure is

too low (see dia‐

gram),

•

The required

cooling output is

not delivered.

•

High pressure is

normal,

Low pressure is

too low (see dia‐

gram),

•

The required

cooling output is

not delivered.

Note

If no fault can be found for this complaint, purge (clean) refrigerant

circuit with refrigerant R134a ⇒ page 67 . If this is not possible in

your workshop, blow through refrigerant circuit with compressed

air and dry with nitrogen ⇒ page 65 .

10. Checking pressures on vehicles

145

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Possible deviation from specifica‐

tion

Possible cause of fault

Rectifying fault

lk

•

High pressure increases only

slightly above the pressure

measured when the engine is

stopped,

♦ Actuation of air conditioner compressor reg‐ – Check actuation of

ulating valve - N280- is defective.

air conditioner com‐

pressor regulating

valve - N280- .

♦ The air conditioner compressor is defective.

•

Low pressure falls only slightly,

– Purge (clean) refrig‐

erant circuit

The required cooling output is

not delivered.

⇒ page 67 .

– Renew air condi‐

tioner compressor.

•

High pressure rises above spec‐ ♦ Restriction or obstruction in the refrigerant – Feel the refrigerant

ification,

circuit.

circuit with the hand

to sense the tem‐

perature gradient.

•

Low pressure falls only slightly,

The required cooling output is

not delivered.

•

At one component a

temperature gradi‐

ent will be detected:

– If a hose or pipe is

kinked or crushed,

renew it.

– In case of an ob‐

struction, blow

through refrigerant

circuit with com‐

pressed air and ni‐

trogen.

•

If no faults are

found:

– Purge (clean) refrig‐

erant circuit

⇒ page 67 .

•

High pressure and low pressure ♦ Moisture in the refrigerant circuit.

are normal at first, but after a

– Blow through refrig‐

erant circuit with

compressed air and

nitrogen.

while, the high pressure increa‐

ses beyond the specification,

•

The low pressure falls to the di‐

agram value or lower,

– Renew reservoir.

– Repeat the check; if

the system does not

operate correctly

The cooling power called for is

not delivered.

– Purge (clean) refrig‐

erant circuit

⇒ page 67 .

– Recharge refriger‐

ant circuit.

– Repeat check.

146

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Possible deviation from specifica‐

tion

Possible cause of fault

Rectifying fault

lk

•

High pressure is normal,

♦ Actuation of air conditioner compressor reg‐ – Check actuation of

ulating valve - N280- is defective.

air conditioner com‐

pressor regulating

valve - N280- .

•

Low pressure is too low (see di‐

agram),

♦ The air conditioner compressor is defective.

•

The cooling power required is

delivered.

– Purge (clean) refrig‐

erant circuit

⇒ page 67 .

– Renew air condi‐

tioner compressor.

Note

♦ If the fault is “high pressure normal, low pressure too low ” note

the following: if faulty the evaporator could ice up or the re‐

quired cooling output is not delivered.

♦ In this case, the evaporator may ice up although the correct

quantity of refrigerant is present in the refrigerant circuit.

♦ Check the measured value of the evaporator output tempera‐

ture sender - G263- or evaporator temperature sensor -

G308- .

♦ Check the actuation of the air conditioner compressor regu‐

lating valve - N280-

⇒ Rep. gr. 87

Possible deviation from specifi‐

cation

Possible cause of fault

Rectifying fault

•

High pressure normal or too ♦ Too much refrigerant in circuit.

high,

– Extract some refrig‐

erant from the refrig‐

erant circuit.

Low pressure too high (see di‐

agram),

•

The quantity of re‐

frigerant extracted is

about equal to the

prescribed charge

quantity:

The air conditioner compres‐

sor is noisy (especially imme‐

diately after being switched

on),

– Renew the air condi‐

tioner compressor.

•

The required cooling output is

not delivered.

•

The quantity of re‐

frigerant extracted is

significantly greater

than the prescribed

charge quantity:

– Recharge refrigerant

circuit.

– Repeat check.

•

High-pressure and low-pres‐ ♦ Too much refrigerant oil in circuit.

sure are normal,

– Drain refrigerant cir‐

cuit.

The required cooling output is

not delivered.

– Purge (clean) refrig‐

erant circuit

⇒ page 67 .

10. Checking pressures on vehicles

147

lk

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Possible deviation from specifi‐

cation

Possible cause of fault

Rectifying fault

•

High-pressure and low-pres‐

sure are normal,

•

The air conditioner compres‐

sor is noisy (especially imme‐

diately after being switched

on),

•

The cooling power required is

delivered.

Note

♦ Overfilling with refrigerant oil can occur if the refrigerant oil

level was not checked after the air conditioner compressor

was renewed.

♦ If the air conditioner compressor is not to be replaced, drain

refrigerant oil from air conditioner compressor via the drain

plug. From the total amount of refrigerant oil, fill 50 g direct into

air conditioner compressor and fill remainder in refrigerant cir‐

cuit according to ⇒ vehicle-specific workshop manual .

10.6

Checking systems with an expansion

valve, receiver and air conditioner com‐

pressor regulating valve - N280- (with

externally regulated air conditioner com‐

pressor)

Note

♦ Connecting air conditioner service station ⇒ page 126 .

♦ Observe the test prerequisites ⇒ page 127 .

– Raise engine speed to 2,000 rpm.

– Observe air conditioner service station pressure gauge.

Note

♦ Switching pressures for the air conditioner compressor regu‐

lating valve - N280- and the radiator fan - V7- are vehicle-

specific.

♦ Pressures should be measured at the service connections; the

location of these connections is vehicle-specific ⇒ Rep. gr.

87 .

10.6.1

Specifications:

High-pressure side:

Rising from starting pressure (when pressure gauge is connec‐

ted) to 20 bar.

148

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Low-pressure side:

Falling from starting pressure (when pressure gauge is connec‐

ted) to diagram value.

A - Low pressure (measured at the service connection) in bar ab‐

solute pressure.

B - Control current for the air conditioner compressor regulating

valve - N280- .

C - Permitted tolerance range.

Note

♦ Under unfavourable conditions (very high ambient tempera‐

tures, high atmospheric humidity), the pressure on the high-

pressure side can increase to a maximum of 29 bar.

♦ The control current -B- is indicated in the measured values

lk

block.

♦ The high-pressure value measured by the high-pressure

sender - G65- is indicated in the measured values block ⇒

Rep. gr. 87 .

♦ The low pressure is adjusted to within tolerances within the

output range for the air conditioner compressor depending on

the control current for the air conditioner compressor regulat‐

ing valve - N280- .

♦ Under unfavourable conditions (very high ambient tempera‐

tures, high atmospheric humidity), the output may be insuffi‐

cient to achieve the specification in every case.

♦ The set working current for the regulating valve must be great‐

er than 0.3 A to ensure that the regulating valve is reliably

activated.

♦ At the setting “maximum cooling power”, the control current

should be approx. 0.65 A to 0.8 A (vehicle-specific, indicated

in the measured values block) ⇒ Rep. gr. 87 .

♦ Absolute pressure means that 0 bar corresponds to an abso‐

lute vacuum. The normal ambient pressure corresponds to 1

bar absolute pressure. On most pressure gauges, a reading

of 0 bar corresponds to an absolute pressure of one bar (which

is confirmed by the existence of - 1 bar marking beneath the

0 scale marking).

10. Checking pressures on vehicles

149

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Air conditioning system with refrigerant R134a - Edition 10.2014

Possible deviation Possible cause of fault Rectifying fault

from specification

•

High pressure ♦ Actuation of air con‐ – Che_lc_kk ac‐

remains con‐

ditioner compressor

regulating valve -

N280- is defective.

tuation of air

conditioner

compressor

regulating

valve -

stant or increa‐

ses only slightly

(above the pres‐

sure measured

when the engine

is stopped).

♦ Insufficient refriger‐

ant in circuit.

N280- .

– Look for

•

Low pressure

falls quickly to

the diagram val‐

ue or lower.

leaks using

leak detector

and rectify

them.

The required

– Recharge re‐

frigerant cir‐

cuit.

cooling output is

not delivered.

•

High pressure is

normal.

Low pressure

matches the di‐

agram value.

•

The required

cooling output is

not delivered.

•

High pressure is • Insufficient refriger‐ – Extract some

normal.

ant in circuit.

refrigerant

from the re‐

frigerant cir‐

cuit.

Low pressure

too low (see dia‐

gram).

•

The quantity

of refrigerant

extracted is

significantly

less than the

prescribed

charge

•

The required

cooling output is

not delivered.

quantity.

– Look for

leaks using

leak detector

and rectify

them.

– Recharge re‐

frigerant cir‐

cuit.

– Repeat

check.

•

The quantity

of refrigerant

extracted is

about equal

to the pre‐

scribed

charge

quantity.

150

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Possible deviation Possible cause of fault Rectifying fault

from specification

•

Expansion valve de‐ – Renew ex‐

fective

pansion

valve.

– Recharge re‐

frigerant cir‐

cuit.

– Repeat

check.

Note

♦ If no fault can be found for this complaint, purge (clean) re‐

frigerant circuit with refrigerant R134a ⇒ page 67 . If this is not

possible in your workshop, blow through refrigerant circuit with

compressed air and dry with nitrogen ⇒ page 65 .

♦ Check the measured values of the evaporator output temper‐

ature sender - G263- or evaporator temperature sensor -

G308- and actuation of the air conditioner compressor

regulating valve - N280- . If the measured value of the evap‐

orator output temperature sender - G263- or the evaporator

temperature sender - G308- is faulty, the evaporator may ice

up or the cooling output will not be achieved.

♦ If a repeat test after the expansion valve has been renewed

indicates that the air conditioning system is still not operating

correctly, refit the expansion valve and purge the refrigerant

circuit with compressed air and nitrogen. Then renew the air _lk

conditioner compressor and receiver.

♦ In this case, the evaporator may ice up although the correct

quantity of refrigerant is present in the refrigerant circuit.

♦ If the expansion valve is defective (always closed or not open‐

ing wide enough) the air conditioner compressor regulating

valve - N280- will be set to maximum power and the low-pres‐

sure value will fall to the diagram value or less (the air condi‐

tioner compressor is drawing the refrigerant out of the low-

pressure side). However, since no refrigerant can flow through

the expansion valve, the required cooling power is not deliv‐

ered, and it can be that the high-pressure value does not rise

at all or not enough, since no energy exchange is occurring.

Possible deviation from specifica‐

tion

Possible cause of fault

Rectifying fault

•

High pressure increases only

slightly above the pressure

measured when the engine is

stopped.

♦ Actuation of air conditioner compressor reg‐ – Check actuation of

ulating valve - N280- is defective.

air conditioner com‐

pressor regulating

valve - N280- .

•

Low pressure falls only slightly.

The required cooling output is

not delivered.

10. Checking pressures on vehicles

151

lk

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Possible deviation from specifica‐

tion

Possible cause of fault

Rectifying fault

♦ The air conditioner compressor is defective. – Extract refrigerant.

– Purge (clean) refrig‐

erant circuit

⇒ page 67 .

– Renew air condi‐

tioner compressor.

– Recharge refriger‐

ant circuit.

•

High pressure increases be‐

yond the specification.

♦ Actuation of air conditioner compressor reg‐ – Check actuation of

ulating valve - N280- is defective.

air conditioner com‐

pressor regulating

valve - N280- .

•

Low pressure falls quickly to the

diagram value or lower.

The required cooling output is

not delivered.

♦ Restriction or obstruction in the refrigerant – Feel the refrigerant

circuit.

circuit with the hand

to sense the tem‐

perature gradient.

•

At one component a

temperature gradi‐

ent will be detected:

– If a hose or pipe is

kinked or crushed,

renew it.

– In case of an ob‐

struction, blow

through refrigerant

circuit with com‐

pressed air and ni‐

trogen.

– Recharge refriger‐

ant circuit.

– Repeat check.

•

If no faults are

found:

– Purge (clean) refrig‐

erant circuit

⇒ page 67 .

– Recharge refriger‐

ant circuit.

– Repeat the check; if

the system does not

operate correctly

♦ Expansion valve defective.

– Extract refrigerant.

– Renew the expan‐

sion valve and re‐

ceiver.

– Recharge refriger‐

ant circuit.

152

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

♦ In this case, the evaporator may ice up although the correct

quantity of refrigerant is present in the refrigerant circuit.

lk

♦ If the expansion valve is defective (always closed or not open‐

ing wide enough) the air conditioner compressor regulating

valve - N280- will be set to maximum power and the low-pres‐

sure value will fall to the diagram value or less (the air condi‐

tioner compressor is drawing the refrigerant out of the low-

pressure side). However, since no refrigerant can flow through

the expansion valve, the required cooling power is not deliv‐

ered, and it can be that the high-pressure value does not rise

at all or not enough, since no energy exchange is occurring.

Possible deviation from specifica‐

tion

Possible cause of fault

Rectifying fault

•

High pressure and low pressure ♦ Actuation of air conditioner compressor reg‐ – Check actuation of

are normal at first, but after a

time the high pressure increa‐

ses beyond the specification.

ulating valve - N280- is defective.

air conditioner com‐

pressor regulating

valve - N280- .

•

After a time, the low pressure

falls to the diagram value or low‐

er.

•

The cooling power called for is

not delivered.

High pressure and low pressure ♦ Moisture in the refrigerant circuit.

are normal at first, but after a

– Extract refrigerant.

longer drive, the low pressure

– Blow through refrig‐

erant circuit with

compressed air and

nitrogen.

falls to below the specification

(evaporator iced up).

– Renew receiver to‐

gether with dryer.

– Evacuate refriger‐

ant circuit for at

least 3 hours.

– Recharge refriger‐

ant circuit.

– Repeat the check; if

the function is not

OK

– Purge (clean) refrig‐

erant circuit

⇒ page 67 .

– Recharge refriger‐

ant circuit.

– Repeat check.

10. Checking pressures on vehicles

153

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Note

♦ If this complaint occurs after a longer period of operation or

only occasionally (the low pressure falls below the specifica‐

tion and the evaporator ices up) it is sufficient only to renew

the dryer (fitted within the receiver). Check the quantity of re‐

frigerant oil. Then evacuate the refrigerant circuit for at least 3

hours.

♦ In case of this complaint, it is not initially necessary to purge

the refrigerant circuit with compressed air and nitrogen, since

as a rule only a small quantity of moisture will have accumu‐

lated in the system, which can be removed by a longer evac‐

uation period.

lk

♦ In this case, the evaporator may ice up although the correct

quantity of refrigerant is present in the refrigerant circuit.

Possible deviation from specifica‐

tion

Possible cause of fault

Rectifying fault

•

High pressure normal, low pres‐ ♦ Actuation of air conditioner compressor reg‐ – Check actuation of

sure too low (see diagram), the

required cooling power is deliv‐

ered.

ulating valve - N280- is defective.

air conditioner com‐

pressor regulating

valve - N280- .

♦ Expansion valve defective.

– Extract refrigerant.

– Purge (clean) refrig‐

erant circuit

⇒ page 67 .

– Renew the expan‐

sion valve and re‐

ceiver.

– Recharge refriger‐

ant circuit.

– Repeat the check; if

the system does not

operate correctly

– Renew the air con‐

ditioner compres‐

sor.

♦ The air conditioner compressor is defective. – Extract refrigerant.

– Purge (clean) refrig‐

erant circuit

⇒ page 67 .

– Renew the air con‐

ditioner compres‐

sor.

– Recharge refriger‐

ant circuit.

– Repeat check.

154

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 fault is “high pressure normal, low pressure too low ” note

the following: if faulty the evaporator could ice up or the re‐

quired cooling output is not delivered.

♦ In this case, the evaporator may ice up although the correct

quantity of refrigerant is present in the refrigerant circuit.

lk

♦ Check the measured values of the evaporator output temper‐

ature sender - G263- or evaporator temperature sensor -

G308- and actuation of the air conditioner compressor

regulating valve - N280- . If the measured value at the high-

pressure sender - G65- is faulty, the evaporator can ice up or

the required cooling power is not delivered.

♦ If the defect is in the air conditioner compressor regulating

valve - N280- (the regulating valve is not activated, but the air

conditioner compressor still runs), it is not necessary to blow

through the refrigerant circuit. If this fault occurs, it is sufficient

to renew the air conditioner compressor (check the refrigerant

oil quantity in the air conditioner compressor).

♦ If the expansion valve is defective (always closed or not open‐

ing wide enough) the air conditioner compressor regulating

valve - N280- will be set to maximum power and the low-pres‐

sure value will fall to the diagram value or less (the air condi‐

tioner compressor is drawing the refrigerant out of the low-

pressure side). However, since no refrigerant can flow through

the expansion valve, the required cooling power is not deliv‐

ered, and it can be that the high-pressure value does not rise

at all or not enough, since no energy exchange is occurring.

⇒ Rep. gr. 87

Possible deviation from specifi‐

cation

Possible cause of fault

Rectifying fault

•

High pressure normal or too ♦ Actuation of air conditioner compressor reg‐ – Check actuation of

high.

ulating valve - N280- is defective.

air conditioner com‐

pressor regulating

valve - N280- .

Low pressure too low (see di‐ ♦ Too much refrigerant in circuit.

agram).

– Extract some refrig‐

erant from the refrig‐

erant circuit.

The air conditioner compres‐

sor is noisy (especially imme‐

diately after being switched

on).

•

The quantity of re‐

frigerant extracted is

about equal to the

prescribed charge

quantity:

•

The required cooling output is

not delivered.

– Renew the air condi‐

tioner compressor.

•

The quantity of re‐

frigerant extracted is

significantly greater

than the prescribed

charge quantity:

– Recharge refrigerant

circuit.

– Repeat check.

10. Checking pressures on vehicles

155

lk

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Possible deviation from specifi‐

cation

Possible cause of fault

Rectifying fault

♦ Too much refrigerant oil in circuit.

– Drain refrigerant cir‐

cuit.

•

The quantity of re‐

frigerant extracted is

about equal to the

prescribed charge

quantity.

– Purge (clean) refrig‐

erant circuit

⇒ page 67 .

– Recharge refrigerant

circuit.

– Repeat check.

♦ Expansion valve defective.

– Drain refrigerant cir‐

cuit.

– Renew the expan‐

sion valve and re‐

ceiver.

– Recharge refrigerant

circuit.

– Repeat the check; if

the system does not

operate correctly

– Renew the air condi‐

tioner compressor.

♦ The air conditioner compressor is defective. – Drain refrigerant cir‐

cuit.

– Purge (clean) refrig‐

erant circuit

⇒ page 67 .

– Renew the air condi‐

tioner compressor.

•

The quantity of re‐

frigerant extracted is

significantly greater

than the prescribed

charge quantity.

– Recharge refrigerant

circuit.

– Repeat check.

156

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 defect is in the air conditioner compressor regulating

valve - N280- (the regulating valve is not activated, but the air

conditioner compressor still runs), it is not necessary to blow

through the refrigerant circuit. If this fault occurs, it is sufficient

to renew the air conditioner compressor (check the refrigerant

oil quantity in the air conditioner compressor).

♦ Overfilling with refrigerant oil can occur if the refrigerant oil

level was not checked after the air conditioner compressor

was renewed.

♦ If the air conditioner compressor is not to be replaced, drain

refrigerant oil from air conditioner compressor via the drain

plug. From the total amount of refrigerant oil, fill 50 g direct into

air conditioner compressor and fill remainder in refrigerant cir‐

cuit according to ⇒ vehicle-specific workshop manual .

♦ If the expansion valve is defective (always closed or not open‐

ing wide enough) the air conditioner compressor regulating

valve - N280- will be set to maximum power and the low-pres‐

sure value will fall to the diagram value or less (the air condi‐

tioner compressor is drawing the refrigerant out of the low-

pressure side). However, since no refrigerant can flow through

the expansion valve, the required cooling power is not deliv‐

ered, and it can be that the high-pressure value does not rise

at all or not enough, since no energy exchange is occurring.

Possible deviation from specifi‐

cation

Possible cause of fault

Rectifying fault

•

High pressure and low pres‐ ♦ Actuation of air conditioner compressor reg‐ – Check actuation of

sure are normal.

ulating valve - N280- is defective.

air conditioner com‐

pressor regulating

valve - N280- .

lk

•

The required cooling output is ♦ Too much refrigerant oil in circuit.

not delivered.

– Purge (clean) refrig‐

erant circuit

⇒ page 67 .

•

High pressure and low pres‐ ♦ Too much refrigerant oil in circuit.

sure are normal.

– Drain refrigerant cir‐

cuit.

The air conditioner compres‐

sor is noisy (especially imme‐

diately after being switched

on).

– Purge (clean) refrig‐

erant circuit

⇒ page 67 .

– Recharge refrigerant

circuit.

•

The cooling power required is

delivered.

– Repeat check.

♦ Expansion valve defective.

– Renew expansion

valve.

10. Checking pressures on vehicles

157

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Note

♦ Overfilling with refrigerant oil can occur if the refrigerant oil

level was not checked after the air conditioner compressor

was renewed.

♦ If the air conditioner compressor is not to be replaced, drain

refrigerant oil from air conditioner compressor via the drain

plug. From the total amount of refrigerant oil, fill 50 g direct into

air conditioner compressor and fill remainder in refrigerant cir‐

cuit according to ⇒ vehicle-specific workshop manual .

♦ If the expansion valve is defective (always open) the evapo‐

rator temperature will no longer be regulated so that only

gaseous refrigerant exits the evaporator. It is then possible

that under certain operating conditions, drops of liquid will be

drawn into the air conditioner compressor, which will hen

cause noise (because liquid is incompressible).

10.7

With expansion valve, receiver and

lk

electrical air conditioner compressor

Note

The electrical air conditioner compressor does not have an air

conditioner compressor regulating valve - N280- . Regulation

takes place via the speed of the air conditioner compressor. The

air conditioner compressor contains the control electronics and a

G-supercharger that impels the refrigerant.

158

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

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

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

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

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‐

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

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‐

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

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

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♦ 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

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

Air conditioning system with refrigerant R134a - Edition 10.2014

12

Testing equipment and tools

12.1

List of test equipment, tools and materi‐

als

Note

This list is an overview of the test equipment, tools and materials

necessary for professional repairs to the refrigerant circuit.

Caution

Non-authorised tools or materials (e.g. leak inhibitor additive)

may cause damage or adversely influence the system.

Only tools and materials approved by the manufacturer may

be used.

Use of non-approved tools or materials will render the warranty

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void.

12.1.1

Tools and materials available from dis‐

tribution centre or importer

Overview

page

Air conditioner service station - VAS 6007A- ,

other air conditioner service stations ⇒

V.A.G workshop equipment catalogue .

⇒ page 168

Leak detector - V.A.G 1796-

Leak detecting system - VAS 6196-

Leak detection additive - VAS 6196/1-

⇒ page 169

not illustrated

⇒ page 170

Leak detecting system - VAS 6201- or later

model

Air conditioner service station - VAS 6380-

with purging device or air conditioner service

station with purging device - VAS 6337- (lat‐

est available air conditioner service stations

⇒ V.A.G workshop equipment catalogue ).

♦ With integrated program for purging re‐

frigerant circuit using refrigerant R134a.

not illustrated

Purging device for refrigerant circuits - VAS

6337/1- , (other available refrigerant circuit

purging devices ⇒ V.A.G workshop equip‐

ment catalogue .

⇒ page 169

♦ For purging refrigerant circuit using re‐

frigerant R134a. To use also on older air

conditioner service stations (purging de‐

vice must then be carried out manually)

with a reservoir volume of at least 10 kg

refrigerant R134a.

12. Testing equipment and tools

165

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Overview

page

Purging device for refrigerant circuits - VAS

6336/1- , (other available refrigerant circuit

purging devices ⇒ V.A.G workshop equip‐

ment catalogue .

⇒ page 169

♦ For purging refrigerant circuit using re‐

frigerant R134a. To use also on older air

conditioner service stations (purging de‐

vice must then be carried out manually)

with a reservoir volume of at least 10 kg

refrigerant R134a.

Adapter case VW/Audi passenger vehicle

set -VAS 6338/1- for refrigerant circuits with

refrigerant R134a.

not illustrated

♦ For connection of air conditioner service

station to refrigerant circuit and to bridge

certain components during purging with

refrigerant R134a or blowing through with

compressed air or nitrogen.

Adapter case commercial vehicle set -

VAS 6338/50- for refrigerant circuits with re‐

frigerant R134a.

♦ For connection of air conditioner service

station to refrigerant circuit and to bridge

certain components during purging or

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blowing through.

Ultrasonic air conditioner cleaning unit - VAS not illustrated

6189A-

♦ To remove unpleasant odours originating

from air conditioning system.

Suction feed spray-gun - V.A.G 1538-

♦ V.A.G 1538/5, probe for evaporator

cleaning, short

not illustrated

♦ V.A.G 1538/6, probe for evaporator

cleaning, long

♦ V.A.G 1538/7, probe for evaporator

cleaning, 700 mm (CV)

♦ Cleaner D 600 100 A1

♦ Cleaning solution for evaporator D 600

100 A2

♦ To remove unpleasant odours from evap‐

orator

Release tools case - VAS 6127-

♦ To open refrigerant pipes.

⇒ page 170

⇒ page 171

Release tools - VAS 6127/1-3-

♦ To open refrigerant pipes.

Counterhold - V.A.G 1616-

♦ For coupling plate (air conditioner com‐

pressor made by “Sanden”).

Puller - V.A.G 1616/1- for magnetic clutch

(Sanden air conditioner compressor).

⇒ page 171

Magnetic clutch puller - V.A.G 1719- (Zexel

air conditioner compressor).

Adapter set for refrigerant circuit - V.A.G

1785/1-10- R134a.

166

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Overview

page

Combination fine filter unit for compressed

air systems; oil, dirt and water separator as

used for paint gun systems ⇒ Workshop

equipment catalogue .

not illustrated

O-ring ⇒ Parts catalogue .

Refrigerant oil ⇒ Parts catalogue .

Socket insert - T10364- for valves of service

connections on HP/LP side of refrigerant cir‐

cuit.

not illustrated

⇒ page 172

12.1.2

Tools and materials commercially avail‐

able

Caution

Non-authorised tools or materials (e.g. leak inhibitor additive)

may cause damage or adversely influence the system.

Only tools and materials approved by the manufacturer may

be used.

Use of non-approved tools or materials will render the warranty

void.

Overview

page

Fin comb

⇒ page 172

⇒ page 173

Charging hoses 5/8"-18 UNF with valve opener

Connector piece for pressure bottles for refrigerant and sealing ring with quick-

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release coupling or threaded connector 5/8"-18 UNF

Valve caps 5/8" -18 UNF

Manifold gauge with pressure limiter for nitrogen

⇒ page 173

⇒ page 174

Quick-release coupling adapter for service connections, 2 included in items

supplied with air conditioner service station

Open ring spanners of widths matching those of the threaded connections on

the refrigerant pipes.

not illustrated

Valve opener for charging hoses

Connection nipple for tapered seal 5/8"-18 UNF

Compressed air gun with rubber nozzle

Hand shut-off valve 5/8" - 18 UNF

Recycling bottle for refrigerant R134a

Digital thermometer

Protective gloves

Protective goggles

Refrigerant R134a with pressure bottle (contents as required)

Nitrogen in pressure bottle

Strap wrench (oil filter) as counterhold for poly V-belt pulley

not illustrated

12. Testing equipment and tools

167

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

Air conditioning system with refrigerant R134a - Edition 10.2014

12.1.3

Tools to be made locally

Overview

page

Charging hose with connector to the work‐

shop's compressed air system

⇒ page 174

12.1.4

Tools and materials available from dis‐

tribution centre or importer

Caution

Non-authorised tools or materials (e.g. leak inhibitor additive)

may cause damage or adversely influence the system.

Only tools and materials approved by the manufacturer may

be used.

Use of non-approved tools or materials will render the warranty

void.

Air conditioning service station - VAS 6007A- (and further service

stations currently available)

⇒ Workshop equipment

♦ The procedures for testing, extracting (recycling), evacuating

and charging should be carried out in accordance with the re‐

spective user's manual.

♦ The installed filter and dryer must be renewed at the latest at

lk

the end of the period of use specified in the operating instruc‐

tions and every time that the station is emptied (keep replace‐

ment filter on hand. they can be ordered from the manufacturer

of the device, see user's manual.

♦ Air conditioner service stations or purging devices approved

by VW but not shown here may also be used.

⇒ Workshop equipment

Note

♦ This air conditioner service station incorporates the following

common individual devices: charging cylinder, manifold

gauge, vacuum pump, shut-off valves and charging hoses.

♦ This air conditioner service station includes one of each type

of quick-release coupling (for high-pressure and low-pressure

side service connections).

168

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Purging device for refrigerant circuits - VAS 6337/1- from “Behr”

or later model.

Note

♦ With filter -1- and two large cylindrical sight glasses

♦ The filter in the purging device for refrigerant circuits should

be changed after about 2 purging cycles (depending on the

level of contamination from the purged refrigerant circuits). If

a heavily contaminated refrigerant circuit is purged (the refrig‐

erant oil from the refrigerant circuit is black and viscous or

there are large amounts of shavings in the refrigerant circuit)

renew filter after purging refrigerant circuit.

Purging device for refrigerant circuits - VAS 6336/1- from “Waeco”

or later model.

Note

♦ With filter -1- and one sight glass

♦ The filter in the purging device for refrigerant circuits should

be changed after about 2 purging cycles (depending on the

lk

level of contamination from the purged refrigerant circuits). If

a heavily contaminated refrigerant circuit is purged (the refrig‐

erant oil from the refrigerant circuit is black and viscous or

there are large amounts of shavings in the refrigerant circuit)

renew filter after purging refrigerant circuit.

Leak detector - V.A.G 1796-

Leak detecting system - VAS 6196-

12. Testing equipment and tools

169

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Leak detecting system VAS 6201 or later model

Release tool - VAS 6127- case comprising release tool - VAS

6127/1- release tool - VAS 6127/2- and release tool - VAS 6127/3-

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Release tool - VAS 6127/1- release tool - VAS 6127/2-

♦ Blue 1/2 inch

♦ Black 5/8 inch

♦ Red 3/8 inch

♦ White 3/4 inch

Release tool - VAS 6127/3-

♦ Green NW 8 for high-pressure line

♦ Black NW 13 for low-pressure line

170

Rep. gr.00 - Technical data

lk

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Counterhold - V.A.G 1616- for clutch pulley (for “Sanden” air con‐

ditioner compressors)

Puller - V.A.G 1616/1- for clutch pulley (for “Sanden” air condi‐

tioner compressors)

Magnetic clutch puller - V.A.G 1719- (for “Zexel” air conditioner

compressors)

Adapter set for refrigerant circuit - V.A.G 1785/1-10-

♦ Adapter to clean refrigerant circuit (flushing with refrigerant

R134a) ⇒ page 67 or blowing through with compressed air or

nitrogen ⇒ page 65

A - 5/8"-18 UNF thread for conical surface seal

B - Cap nuts (for connection with O-ring) with thread

♦ M 18x1.5 V.A.G 1785/1

♦ M 20x1.5 V.A.G 1785/2

♦ M 24x1.5 V.A.G 1785/3

♦ M 28x1.5 V.A.G 1785/4

A - 5/8"-18 UNF thread for conical surface seal

B - Threaded union for O-ring

12. Testing equipment and tools

171

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Air conditioning system with refrigerant R134a - Edition 10.2014

♦ M 18x1.5 V.A.G 1785/5

♦ M 20x1.5 V.A.G 1785/6

♦ M 24x1.5 V.A.G 1785/7

♦ M 28x1.5 V.A.G 1785/8

Valve adapters

A - 5/8"-18 UNF thread for conical surface seal

B - Internal thread with valve opener M 10x1.25 V.A.G 1785/9 (for

connections with valves on the high-pressure side) M 12x1.5

V.A.G 1785/10 (for connections on the low-pressure side)

Note

lk

♦ There is a Schrader valve screwed into connection -A-.

♦ A valve opener must be fitted into the charging hose connec‐

tion.

Socket insert - T10364- for valves of service connections on HP/

LP side of refrigerant circuit

12.1.5

Tools and materials commercially avail‐

able

Fin comb

172

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

Charging hoses

5/8"-18 UNF valve

Note

♦ Various colours of charging hose can be used, 1,800 mm long.

♦ Maintain a stock of valve openers and spare seals.

Connector piece for pressure bottles for refrigerant with sealing

ring, quick-release coupling or threaded connector 5/8"-18 UNF

lk

Valve caps with replacement seals (for 5/8''-18 UNF threads)

Seals can also be used for charging hoses.

Manifold gauge with pressure reducer for nitrogen (maximum re‐

duction pressure: 15 bar)

1 - Manifold gauge with pressure reducer

2 - Pressure hose (internal diameter 5 mm, length 2 m) with

hose junctions

3 - Nitrogen bottle

4 - Hose fitting

Note

Hose junctions for connection to the adapter set for refrigerant

circuit - V.A.G 1785- with 5/8"-18 UNF threads or quick-release

coupling adapter for service connections to refrigerant circuit.

12. Testing equipment and tools

173

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Air conditioning system with refrigerant R134a - Edition 10.2014

Quick-release coupling adapter for service connection

♦ High-pressure side with nominal diameter of 16 mm

♦ Low-pressure side with nominal diameter of 13 mm

Note

These quick-release couplings are supplied with the air condi‐

tioner service station.

12.1.6

Tools to be made locally

Charging hose with connector to the workshop's compressed air

system

A - Charging hose 5/8" - 18 UNF** (version with large internal

diameter)

B - Connector for workshop compressed air system** (use only

with filter and dryer for compressed air)

** Tools and materials which are commercially available

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174

Rep. gr.00 - Technical data

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

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