Get Workingwiththeairconditionerservicestation Guide for Volkswagen LT Van Second Generation (1996-2006)

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

Air conditioning system with refrigerant R134a - Edition 10.2014

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

47

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

Air conditioning system with refrigerant R134a - Edition 10.2014

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.

48

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

– 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

49

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

Air conditioning system with refrigerant R134a - Edition 10.2014

– 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.

50

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

– 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

51

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

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.

52

Rep. gr.00 - Technical data

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

Air conditioning system with refrigerant R134a - Edition 10.2014

– 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

53

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

Air conditioning system with refrigerant R134a - Edition 10.2014

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).

54

Rep. gr.00 - Technical data

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

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