Get Air conditioning system Refrigerant circuit -> 1.4 Investigating leaks Guide for Volkswagen Sharan VAN Second Generation (2010-2023)

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Air conditioning systems with refrigeranR1234yf - General information - Edition 07.2017

1.4

Investigating leaks

⇒ “1.4.1 General information abouinvestigating leaks in the re‐

frigerancircuit”, page 68

⇒ “1.4.2 Searching for leaks in refrigerancircuits using an elec‐

tronic leak detector”, page 69

⇒ “1.4.3 Searching for leaks with UV leak detection system”, page

71

⇒ “1.4.4 Detecting leaks in a vacuum tesusing air conditioner

service station , or in a pressure test”, page 77

⇒ “1.4.5 Detecting leaks in a pressure tes(with nitrogen or com‐

pressed air)”, page 77

1.4.1

General information abouinvestigating

leaks in the refrigerancircui

Note

♦ Small leaks can be detected with e.g. an electronic leak de‐

tector or a UV leak detector lamp.

♦ This workshop manual describes 2 ways of tracing leaks in

refrigerancircuits. These procedures have been tested and

lead to a reliable resulunder the differenusage conditions if

they are performed correctly and in accordance with the spe‐

cific complaint.

♦ Various methods are offered in the open markewith which

leaks in refrigerancircuits can be traced. These methods are

noable to provide clear results in all cases and, unless the

exacprocedure is adhered to, they can also resulin various

components of the refrigerancircuibeing identified as having

leaks even though they do not. Furthermore, certain process‐

es can cause preliminary or permanendamage to the com‐

ponents of the refrigerancircui

♦ Components thaare found to be leaking musnobe repaired.

They musbe renewed instead.

♦ A leaking refrigerancircuimusnobe charged with refriger‐

ant. Therefore, evacuate an empty refrigerancircuiand

check for leaks before charging the system with refrigeran

⇒ “2.5 Evacuating refrigerancircuit”, page 140 .

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Note

♦ VW/Volkswagen/Audi does noendorse the use of chemical

substances (leak inhibitor additives) for purposes of sealing

leaks in refrigerancircuits.

♦ Chemical substances used to seal leaks form deposits in the

refrigerancircuit. These can impair the function of the air con‐

ditioning system and cause the air conditioning system (and

your air conditioner service station ) to fail.

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♦ These chemical substances (leak stop additives) reacmostly

with the ambienair or the humidity to stop leaks in the refrig‐

erancircuit. They cause deposits to build up in the refrigeran

circui(and your air conditioner service station ), cause valves

to malfunction and defects in other components with which

they come into contact. These deposits cannobe completely

removed from the components (noeven by cleaning/flush‐

ing). The refrigerancircuican only be repaired by replacing

all components thahave come into contacwith this sub‐

stance.

1.4.2

Searching for leaks in refrigerancircuits

using an electronic leak detector

Special tools and workshop equipmenrequired

♦ Electronic leak detector or proprietary device

Note

♦ Leaks in R1234yf refrigerancircuits can only be found using

electronic leak detection devices designed for R1234yf refrig‐

erant.

♦ The various refrigerants have a differenmolecular structure.

The sensors of electronic leak detection devices are adapted

to these molecules. If an electronic leak detection device is

used thais nodesigned for R1234yf refrigerant, iwill no

respond to R1234yf refrigeranaall or only in larger concen‐

trations in the vicinity of the leak. For this reason, electronic

leak detection devices designed only for R134a refrigeran

cannobe used for leak detection in the R1234yf refrigeran

circuit.

♦ Depending on the type of heater and air conditioner unit, a leak

from the evaporator can be investigated by holding the tes

probe of the leak detector againsthe glove compartmen

cooler connection in the heater and air conditioner unit, or by

holding the tesprobe againsthe open condensation drain

connection of the heater and air conditioner uniwith the con‐

densation drain hose pulled off.

Performing leak detection on a completely empty refrigerancir‐

cuicaused by a leak:

Note

With a completely empty refrigerancircuit, proceed as follows to

ensure thano more refrigeranthan necessary enters the envi‐

ronmenduring testing:

– Evacuate refrigerancircuiusing air conditioner service sta‐

tion ⇒ “2.5 Evacuating refrigerancircuit”, page 140 .

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Note

♦ If a larger leak is detected during the evacuation process, de‐

termine the cause and rectify as described

⇒ “2.5 Evacuating refrigerancircuit”, page 140 .

♦ If during the evacuation process no leak is detected or a very

small leak is detected thacannobe located using the vacuum

test, proceed as follows.

– If the refrigerancircuiis completely empty, charge the system

with approx. 10% of refrigeranand perform leak detection in

the same way as per a fully charged refrigerancircui

⇒ page 70 .

Performing leak detection on a charged refrigerancircuit:

– Switch off ignition.

– Start the leak detector according to the operating instructions.

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– Always hold probe tip under location of suspected leak.

If, inherenof the design, the rate of clicks rises or a wailing noise

is heard, a leak has been detected ⇒ operating instructions for

leak detector .

Note

♦ Refrigerangas is quickly dispersed by movemenof air.

Draughts mustherefore be avoided during leak detection.

♦ Refrigerangas is heavier than air and therefore sinks athe

poinawhich iescapes.

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1.4.3

Searching for leaks with UV leak detec‐

tion system

Note

♦ Certain leaks are difficulor impossible to find using an elec‐

tronic leak detection device. To investigate these leaks, leak

detection can be performed using the leak detection system

⇒ Electronic parts catalogue .

♦ Refrigeranand refrigeranoil leaks ouof the refrigerancircui

when the circuihas a leak. This oil generally remains in the

vicinity of the leak location. To make the oil visible under^lU^kV

light, a small amounof fluorescenfluid musbe added to the

refrigerancircuit. This fluid (PAG oil with an additive which

lights up under UV light) is injected into the refrigerancircui

and distributed with the refrigeranoil when the air conditioning

system is switched on.

♦ The air conditioning system musbe operated for aleas

60 minutes to ensure thathe injected leak detecting additive

is distributed throughouthe entire refrigerancircui(air con‐

ditioner compressor musrun). The leak may become visible

under UV lighafter a shorperiod, buthis depends on the

size of the leak.

♦ The refrigeranoil with additive, which lights up under UV light,

can be added directly in an open circuior charged after emp‐

tying the circuiwith air conditioner service station via the

service connection.

♦ If the leak detection additive is added to the refrigerancircui

via the service connection, a small amounof leak detection

additive will be deposited in the service connection. Carefully

remove any deposits so thathis area is nomistaken for a leak

during subsequenleak detection.

♦ If a componenfrom a circuiin which leak detection additive

is filled is renewed, thoroughly clean the connection points to

other components after assembling the refrigerancircuit. Dur‐

ing subsequenleak detection, deposits of leak detection ad‐

ditive could otherwise be mistaken for leaks athe connecting

point.

♦ When purging the refrigerancircuit, refrigeranoil and there‐

fore also leak detection additive also enter the air conditioner

service station . The refrigeranoil is separated from the re‐

frigeranin the oil separator of the air conditioner service

station and removed from the air conditioner service station

via the drainage outlet. The drained refrigeranoil may nobe

reused. Imusbe replaced with fresh refrigeranoil.

♦ If leak detection fluid was injected during a previous repair of

the refrigerancircuit, observe the following: do noinjecnew

leak detection fluid unless the refrigeranmachine oil has been

replaced. If only some of the refrigeranmachine oil was re‐

placed then only the respective amounof leak detection fluid

should be injected. If, for example, 100 ml of refrigeranoil is

replaced in a vehicle with 250 ml of refrigeranoil, injeconly

1 ml (cm³) of leak detection additive.

♦ Certain materials and their compounds (e.g. oxidisation prod‐

ucts on components made from aluminium, corrosion protec‐

tion wax, etc.) also lighup under UV light.

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

also be used to add the leak detection additive directly into the

system. See the operating instructions of your air conditioner

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service station ⇒ Operating instructions air conditioner service

station .

Leak detection on an empty, leaking refrigerancircui

– With a completely empty refrigerancircuit, proceed as follows

to ensure thano more refrigeranthan necessary enters the

environmenduring testing:

– Evacuate refrigerancircuiwith air conditioner service station

⇒ “2.5 Evacuating refrigerancircuit”, page 140 .

Note

If a larger leak is detected during the evacuation process, deter‐

mine the cause and rectify as described

⇒ “1.4.4 Detecting leaks in a vacuum tesusing air conditioner

service station , or in a pressure test”, page 77 and

⇒ “2.5 Evacuating refrigerancircuit”, page 140 .

If during the evacuation process no leak is detected or a very

small leak is detected thacannobe located during evacuation,

proceed as follows.

Note

♦ Only use UV leak detection additive approved for R1234yf re‐

frigerant.

♦ The leak detection additive contains refrigeranoil for the mos

part. Since special refrigeranoils are required for R1234yf

refrigerant, only UV leak detection additives may be used tha

use this oil as a carrier. UV leak detection additives developed

for R134a refrigeranare therefore unsuitable.

♦ For refrigerancircuits with R1234yf and R134a refrigerant,

differenrefrigeranoils (PAG oils) are used, which is why iis

importanto ensure correcallocation of the leak detection ad‐

ditive (PAG oil with an additive thalights up under UV light).

♦ Charge the refrigerancircuiwith UV leak detection additive

using the air conditioner service station ⇒ page 75 .

♦ Charge the refrigerancircuiwith UV leak detection additive

using the leak detection system ⇒ page 75 .

– Charge the refrigerancircuiwith the specified amounof UV

leak detection additive and the requisite amounof refrigeran

⇒ page 72 , ⇒ “2.6 Charging refrigerancircuit”, page 146

and ⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data .

– Run the air conditioning system for aleas60 minutes with

the air conditioner compressor switched on.

– Investigate leaks with UV leak detection system

⇒ page 75 .

Charge the refrigerancircuiwith UV leak detection additive using

the air conditioner service station .

– Charge the refrigerancircuiwith UV leak detection additive

and the requisite amounof refrigeranusing air conditioner

service station ⇒ “2.6 Charging refrigerancircuit”, page 146

and ⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data .

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Note

♦ The amounof UV leak detection additive to be charged in the

refrigerancircuiwith a refrigeranoil volume up to 150 cm³

is 3.0 ± 0.5 ml. If the volume of refrigeranoil in the refrigeran

circuiis greater, more UV leak detection additive musbe

added accordingly, e.g. 5.0 ± 0.5 ml in a refrigerancircuiwith

a refrigeranoil volume of 250 cm³. If the UV leak detection

additive is filled with an air conditioner service station , the

volume to be sein your air conditioner service station may

differ. Therefore, observe the relevanoperating instructions

⇒ Operating instructions Air conditioner service station .

♦ For the specific volume of refrigeranoil in the refrigerancir‐

cuit, refer to the vehicle-specific workshop manual ⇒ Heating,

air conditioning; Rep. gr. 00 ; Technical data .

♦ If leak UV leak detection additive was injected during a previ‐

ous repair of the refrigerancircuit, observe the following: do

noinjecnew UV leak detection additive unless the refrigeran

machine oil has been replaced. If only some of the refrigeran

machine oil was replaced then only the respective amounof

UV leak detection additive should be injected. If, for example,

50 ml of refrigeranoil is replaced in a vehicle with 150 ml of

refrigeranoil, injeconly 1.0 ml (cm³) of UV leak detection

additive.

The leak detection system comprises the following parts:

♦ Cleaning agen-3-

♦ UV leak detection lamp -4-

♦ UV absorbing eye protection -5-

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♦ Sticker -6-

♦ Gloves -8-

Note

Items -1-, -2- and -7- in the diagram can be disregarded.

Special tools and workshop equipmenrequired

♦ Leak detecting system

♦ Air conditioner service station with means of adding UV leak

detection additive in the refrigerancircui⇒ Electronic parts

catalogue .

♦ Approved leak detection additive ⇒ Electronic parts cata‐

logue .

– Evacuate the refrigerancircuias per the instructions, and

charge the system with UV leak detection additive and refrig‐

eran⇒ “2.5 Evacuating refrigerancircuit”, page 140 and

⇒ “2.6 Charging refrigerancircuit”, page 146 .

– Wait until the pressures on the high pressure and low pressure

side have settled.

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– Detach the air conditioner service station from the refrigeran

circuiand switch off

⇒ “2.8 Switching off air conditioner service station and sepa‐

rating from refrigerancircuit”, page 151 .

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– Attach a label close to the service connections thashows tha

the refrigerancircuihas been injected with a UV leak detec‐

tion additive.

– Remove any remains of UV leak detection additive from the

service connection e.g. with absorbenpaper, and clean the

area with cleaning agen- VAS 6201/3- .

– Seal the service connection with a cap.

– Bring the air conditioning system into operation.

– Run the air conditioning system for aleas60 minutes with

the air conditioner compressor switched on.

– Search for leaks in the refrigerancircuiusing a UV lamp

⇒ page 75 .

Searching for leaks in refrigerancircuiusing a UV lamp

CAUTION

Risk of eyes being dazzled by UV light.

– Wear protective goggles.

– Never glare into the UV lamp.

– Never poina UV lamp aanother person.

– On vehicles with high-voltage system, switch off “stationary air

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conditioning” function (deactivate)⇒ Owner's Manual and ⇒

Operating instructions of infotainment/MMI .

– Switch off ignition.

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Note

♦ The air conditioning system musbe operated for aleas

60 minutes to ensure thathe injected leak detecting additive

is distributed throughouthe entire refrigerancircui(air con‐

ditioner compressor musrun). The leak may become visible

under UV lighafter a shorperiod, buthis depends on the

size of the leak.

♦ Depending on the size and location of the leak, ican take

several days until sufficienrefrigeranoil with UV leak detec‐

tion additive has leaked ouand the leak can be easily identi‐

fied as such.

♦ In the evenof leaks athe evaporator, the additive may be

washed ouwith the condensate and emerge via the conden‐

sate drain. As the evaporator is noaccessible on the majority

of models withoua greaamounof work, a check of the con‐

densed water drain poincan indicate a leaking evaporator.

This does however require the additive to have been in the

refrigerancircuifor a lengthy period (several days).

♦ The protective eye wear is noonly required to protecthe

eyes. Ialso amplifies the illumination of the UV leak detection

additive under the UV lamp.

♦ Depending on how easy iis to reach various components in

the refrigerancircuit, imay be necessary to remove certain

parts from the vehicle (e.g. bumper or air filter).

♦ Only a small amounof refrigeranoil reaches certain areas of

the refrigerancircuiduring operation of the air conditioning

system (e.g. a cap fitted athe top of a receiver installed on

the condenser). If there is a leak in these areas, imay take

quite some time before a sufficienquantity of refrigeranwith

refrigeranoil and additive escapes athis poinand can be li

up under UV lighshowing where the leak is. Athese points,

therefore, imay be more pertinento search for a leak using

an electronic leak detection device

⇒ “1.4.2 Searching for leaks in refrigerancircuits using an

electronic leak detector”, page 69 .

– Position the vehicle in a darker area of the workshop (in day‐

lighor under strong lighting the effecof the UV lamp is greatly

reduced).

– Check accessibility to various components of the refrigeran

circuiand remove parts in the vicinity of the refrigerancircui

thaobstructhe view of the refrigerancircuicomponents

(e.g. noise insulation and bumper).

– Protect eyes with safety goggles.

– Connect UV lamp to a 12 V battery (vehicle battery). Ensure

thathe polarity of the connections is correct.

– Switch on the UV lamp and lighup the components in the

refrigerancircuit. Positions awhich refrigeran- along with

refrigeranoil and leak detection additive - can leak oufluo‐

resce (light-up) under UV light.

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1.4.4

Detecting leaks in a vacuum tesusing

air conditioner service station , or in a

pressure tes

All vehicles

CAUTION

Risk of freezing injury caused by escaping pressurised refrig‐

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erant.

There is a risk of injury to the skin and parts of the body due to

freezing.

– Wear protective gloves.

– Wear protective goggles.

– Extract refrigeranand open the refrigerancircuiimmedi‐

ately afterwards.

– If more than 10 minutes have passed since the refrigeran

was extracted, repeathe extraction process before opening

the refrigerancircuit. Pressure could build up in the refrig‐

erancircuifrom continued evaporation.

– Switch off ignition.

♦ Detecting leaks in a vacuum tesusing air conditioner service

station , or in a pressure tes

⇒ “2.5 Evacuating refrigerancircuit”, page 140

Note

♦ Smaller leaks in the refrigerancircui(less than 100 g refrig‐

eranloss per year) cannousually be found by means of the

vacuum tesor pressure test. The amounof air entering the

system or the nitrogen-air escaping iis too low to detecthe

faulty area through noise.

♦ Iis also noalways possible to detecleaks in the refrigeran

circuiwith more than 100 g refrigeranloss per year by means

of the vacuum tesor pressure test, depending on the envi‐

ronmental conditions (noise around the area, location of leak,

etc.). The air entering the system and nitrogen escaping i

could be too low to generate a noise thawould be noticeable

in the faulty area.

♦ Larger leaks in the refrigerancircui(e.g. more than 100 g

refrigeranloss per day caused by a stone hitting the con‐

denser) can be detected depending on the environmental

conditions, e.g. noise coming from the faulty area, which is

noticeable during the vacuum tesor pressure tes

⇒ “2.5 Evacuating refrigerancircuit”, page 140 .

– Perform vacuum or pressure tes⇒ page 143 .

1.4.5

Detecting leaks in a pressure tes(with

nitrogen or compressed air)

♦ Perform a vacuum tesusing the air conditioner service station

to see if any leaks can be found

⇒ “2.5 Evacuating refrigerancircuit”, page 140 . If a leak can

be detected bunothe exaclocation of the leak, an additional

pressure tescan be performed using nitrogen or compressed

air ⇒ page 143

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Note

♦ Smaller leaks in the refrigerancircui(less than 100 g refrig‐

eranloss per year) cannousually be found by means of the

vacuum tesor pressure test. The amounof air entering the

system or the nitrogen-air escaping iis too low to detecthe

faulty area through noise.

♦ Iis also noalways possible to detecleaks in the refrigeran

circuiwith more than 100 g refrigeranloss per year by means

of the vacuum tesor pressure test, depending on the envi‐

ronmental conditions (noise around the area, location of leak,

etc.). The air entering the system and nitrogen escaping i

could be too low to generate a noise thawould be noticeable

in the faulty area.

♦ Larger leaks in the refrigerancircui(e.g. more than 100 g

refrigeranloss per day caused by a stone hitting the con‐

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denser) can be detected depending on the environmental

conditions, e.g. noise coming from the faulty area, which is

noticeable during the vacuum tesor pressure tes

⇒ “2.5 Evacuating refrigerancircuit”, page 140 .

♦ A larger leak in the refrigerancircuican be detected, for ex‐

ample, by pressurising the circuito a maximum of 15 bar using

cleaned and dried compressed air or nitrogen ⇒ page 124 . If

the leak is large enough, the leakage poincan be detected by

sound as the gas escapes.

Tools required:

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♦ Quick-release coupling adapter -A- (you can also unscrew the

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adapter from your air conditioner service station and use ifor

this test).

♦ Charge hose -A- (e.g. with a M12 x 1.5-6G thread, SAE J639

standard), depending on the thread of the quick-release cou‐

pling adapter (cuoff), with a suitable adapter -B- (for connec‐

tion to the compressed air system used in your workshop or

to a pressure reducer for nitrogen)

♦ Combination fine filter elemenfor compressed air system with

an oil, dirand water separator (to ensure thathe refrigeran

circuiis pressurised with compressed air thais clean, dry and

free of oil) for the leakage teswith compressed air

♦ Manifold gauge with pressure reducer for nitrogen (maximum

reduced pressure: 15 bar) -1-, a full nitrogen gas cylinder -3-

and a charge hose -2- (e.g. with M12 x 1.5-6G thread in

accordance with SAE J639, to which a quick-release coupling

adapter for service connection is fitted) for leakage teswith

nitrogen

– Perform pressure tes⇒ page 143 .

1.5

Renewing components

⇒ “1.5.1 General information abourenewing components”, page

79

⇒ “1.5.2 Renewing leaking or damaged components of empty re‐

frigerancircui(aparfrom air conditioner compressor and re‐

ceiver)”, page 81

⇒ “1.5.3 Renewing leaking or damaged components of charged

refrigerancircui(aparfrom air conditioner compressor and re‐

ceiver)”, page 84

⇒ “1.5.4 Renewing air conditioner compressor with no need to

clean refrigerancircuit”, page 85 .

⇒ “1.5.5 Renewing air conditioner compressor due to leaks or in‐

ternal damage”, page 87

⇒ “1.5.6 Renewing desiccancartridge / receiver after cleaning

refrigerancircuit”, page 88

⇒ “1.5.7 Renewing receiver with no need to clean refrigerancir‐

cuit”, page 90 .

⇒ “1.5.8 Renewing desiccancartridge / desiccanbag with no

need to clean refrigerancircuit”, page 91

1.5.1

General information abourenewing

components

The receiver or desiccancartridge need nobe renewed under

the following circumstances:

♦ The opened refrigerancircuiis sealed immediately with clean

plugs, e.g. from the engine bung se- VAS 6122- .

♦ After an accidenin which there was no damage to the receiv‐

er.

♦ Repairs are performed quickly (nofor longer than the normal

repair time).

♦ The vehicle is no more than 5 years old.

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