Get Technical data Repair notes Guide for Volkswagen Sharan VAN Second Generation (2010-2023)

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Air conditioning systems with refrigeranR1234yf - General information - Edition 07.2017

3

Repair notes

⇒ “3.1 Rules for cleanliness”, page 8

⇒ “3.2 Refrigerancircuiseals”, page 8

⇒ “3.3 Refrigeranand refrigeranoil”, page 9

⇒ “3.4 Handling pressurised tanks/containers”, page 11

⇒ “3.5 Handling refrigerants”, page 12

3.1

Rules for cleanliness

Even small amounts of contamination/soiling can lead to defects.

Therefore, observe the following rules for cleanliness when work‐

ing on the air conditioning system:

♦ Seal open pipes and connections immediately with clean

plugs, for example from the engine bung se- VAS 6122- .

♦ Place removed parts on a clean surface. Cover with lint-free

cloths only.

♦ If repair work cannobe performed immediately, carefully cov‐

er or seal components.

♦ Install only clean parts; do noremove new parts from pack‐

aging until immediately before installing. Do nouse parts tha

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have been stored outside their packaging (e.g. in tool boxes).

♦ Do nowork with compressed air when the system is open.

♦ Protect disconnected electrical connections from dirand wa‐

ter and only reconnecin dry condition.

3.2

Refrigerancircuiseals

♦ Renew seals after removal.

♦ Moisten seals with refrigeranoil before installing.

♦ Ensure proper seating of seals on the pipe or in the groove.

♦ Work in a completely clean environment. Even the smalles

contaminants, e.g. a hair, can cause leaks.

♦ Install only seals resistanto refrigeranR134a/R1234yf and

respective refrigeranoil ⇒ Electronic parts catalogue (ET‐

KA) .

The dimensions -a- and -b- depend on the fitting location of the

seal ⇒ Electronic parts catalogue (ETKA) .

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Rep. gr.00 - Technical data

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Air conditioning systems with refrigeranR1234yf - General information - Edition 07.2017

3.3

Refrigeranand refrigeranoil

⇒ “3.3.1 Importanrepair instructions for refrigeranand refriger‐

anoil”, page 9

⇒ “3.3.2 Refrigeranoil”, page 9

3.3.1

Importanrepair instructions for refriger‐

anand refrigeranoil

•

An air conditioner designed for R1234yf refrigeranmusnever

be charged with R134a refrigerant.

An air conditioner designed for R134a refrigeranmusnever

be charged with R1234yf refrigerant.

The refrigeranoils especially developed for refrigerancircuits

with R1234yf and R134a refrigeranmay nobe used in a re‐

frigerancircuicharged with a differenrefrigeranunless the

relevanpermissions have been granted ⇒ Electronic parts

catalogue and ⇒ Heating, air conditioning system; Rep. gr.

lk

00 ; Technical data; refrigeranoil .

•

Air conditioner service stations which come in contacwith re‐

frigeranmay only be used for the tar refrigerant.

A label -A- is attached in the engine compartmento the lock

carrier or the plenum chamber to provide information on the

refrigeranused.

•

Differenrefrigerants musnever be mixed.

Depending on the type and production period, imay also in‐

dicate the GWP for the refrigeranused.

•

To ensure thaonly R1234yf refrigeranwith a certain purity

level is drawn into the air conditioner service station (R1234yf),

a gas analysis musbe performed before the refrigerancircui

is emptied

⇒ “2.3 Performing gas analysis of refrigerant”, page 134 .

Note

If, during the gas analysis, iis found thathe R1234yf refrigeran

is contaminated with a differengas, imusbe extracted from the

refrigerancircuiand analysed, processed or disposed of as gas

of unknown composition in accordance with the legal require‐

ments ⇒ VW / Audi ServiceNe,

⇒ “2.3 Performing gas analysis of refrigerant”, page 134 and

⇒ “6.2.17 Returning contaminated R1234yf refrigeranfor analy‐

sis, processing or disposal”, page 25 .

3.3.2

Refrigeranoil

CAUTION

Risk of chemical burns from atomised refrigeranoil. Eyes and

other parts of the body could be injured.

– Wear protective gloves.

– Wear protective goggles.

– Never inhale atomised refrigeranoil.

♦ Refrigerant oil mixes with the refrigeran(abou10 to 40%,

depending on compressor type and amounof refrigerant) and

circulates constantly in the system, lubricating the moving

parts.

3. Repair notes

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Air conditioning systems with refrigeranR1234yf - General information - Edition 07.2017

♦ Special synthetic refrigeranmachine oils such as polyalky‐

lene glycol (PAG) oil with certain additives adapted to the

refrigeranoil are used in conjunction with R1234yf air condi‐

tioning systems. This is necessary because e.g. mineral oil

does nomix with R1234yf and, should the additives be miss‐

ing, undesired reactions with the refrigeranor components of

the refrigerancircuicould occur. In addition, the components

of the R1234yf air conditioning system could be attacked if the

mixture circulated within the refrigerancircuiunder pressure

and ahigh temperatures, or the lubricanfilm in the air con‐

ditioner compressor broke down. The use of non-approved

oils can lead to failure of the air conditioning system. There‐

fore, use only approved refrigeranoils ⇒ Electronic parts

catalogue .

♦ Type of oil for R1234yf refrigeranin motor vehicles: PAG oil

with specific additives adapted to R1234yf refrigeran(polyal‐

kylene glycol with certain additives).

♦ The mosimportanproperties are high solubility with refriger‐

ant, good lubricating quality, absence of acid and low water

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content. For this reason, only very specific oils may be used.

Lisof approved refrigeranoils and capacities ⇒ Electronic

parts catalogue and ⇒ Heating, air conditioning system; Rep.

gr. 00 ; Technical data (vehicle-specific workshop manual).

♦ The PAG oils suitable for refrigeranR1234yf are heavily hy‐

groscopic and cannoalways be mixed with other oils. There‐

fore, only use approved refrigeranoils.

♦ Moisture and acids promote ageing of refrigeranoil, causing

ito become dark, viscous and aggressive towards metals.

Containers for refrigeranoil should therefore be kepclosed

to preventhe ingress of moisture. When containers are

opened, they should be closed again immediately.

♦ Due to its chemical properties, refrigeranoil musnobe dis‐

posed of toher with engine oil or gear oil. Refrigeranoil is

to be disposed of as waste oil of unknown origin (observe local

regulations) ⇒ VW / Audi ServiceNe.

♦ For refrigerancircuits with R1234yf refrigerancircuit, only

approved oils may be used for this refrigeranand the air con‐

ditioner compressor installed in the system ⇒ Electronic parts

catalogue and ⇒ Heating, air conditioning system; Rep. gr.

00 ; Technical data .

♦ Refrigerant oil thawas developed for R134a refrigeranis no

suitable for refrigerancircuits with R1234yf refrigeran(as i

is missing specific additives). Therefore, ensure thathe cor‐

rectype is used ⇒ Electronic parts catalogue and ⇒ Heating,

air conditioning system; Rep. gr. 00 ; Technical data; Refrig‐

eranoil .

♦ Refrigerant oil thawas developed for R1234yf refrigeran

could also be suitable for use in refrigerancircuits with R134a

refrigerant. Observe notes ⇒ Electronic parts catalogue and

⇒ Heating, air conditioning system; Rep. gr. 00 ; Technical

data (vehicle-specific workshop manual).

Note

♦ The cylinder in which the refrigeranoil is supplied has a label

from which the expiry date of the refrigeranoil can be gleaned.

♦ This expiry date is nocritical if the cylinder is sealed tight.

♦ Refrigeranoil from a tightly sealed cylinder can also be used

after the expiry date specified on the cylinder.

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Rep. gr.00 - Technical data

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Air conditioning systems with refrigeranR1234yf - General information - Edition 07.2017

Note

♦ Do nostore refrigeranoils open to the atmosphere as they

are very hygroscopic (they readily absorb water).

♦ Always keep the refrigeranoil container and the refrigeran

circuisealed.

♦ Do nouse ester oils (POE oils) as these are currently only

compatible with larger systems under differenoperating con‐

ditions (nosuitable for motor vehicle air conditioning sys‐

tems).

3.4

Handling pressurised tanks/containers

Keep containers tightly sealed in a well ventilated, cool location.

Refrigeranis heavier than air. Should gas escape from a system,

icollects aground level in particular.

Protecagainsheaand direcsunlight, do nokeep in areas with

temperatures higher than 50°C.

Do nokeep in or near cellars or other low lying areas.

Only keep in areas with an adequate flow of air.

Keep containers away from sources of ignition.

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Smoking is forbidden in areas in which R1234yf refrigeranis

kept. Also take measures to prevenelectrostatic discharge.

Secure containers to preventhem falling over.

Secure uprighcylinders to stop them falling over and cylinders

lying flato stop them rolling away.

Containers musnever be thrown.

If they should fall, the containers may become severely deformed

and break open. The refrigeranevaporates immediately, liberat‐

ing considerable force. Flying fragments of cylinders can cause

severe injuries.

To proteccylinder valves, cylinders are only to be transported

with a protective cap screwed on.

Valves may break off if cylinders are noproperly transported.

Do noplace near radiators!

High temperatures can occur near radiators. High temperatures

are also associated with high pressures and the maximum per‐

missible tank pressure may be exceeded.

Do noheaup above 50°C

To mitigate any risk, the pressure vessel regulations stipulate tha

tanks/containers musnobe heated up above 50°C.

Do noexpose to uncontrolled hea

Do noheawith a naked flame under any circumstances. The

local overheating thawill resulcan change the structure of the

container's materials, thereby reducing the safe maximum pres‐

sure limiof the container. There is also a danger of the refrigeran

decomposing due to localised overheating.

Seal empty tanks/containers

Empty refrigerantanks/containers musalways be closed to pre‐

venthe ingress of moisture. Moisture causes steel tanks/con‐

tainers to rust. Rusweakens the tank/container walls. In addition,

3. Repair notes

11

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Air conditioning systems with refrigeranR1234yf - General information - Edition 07.2017

rusparticles which ingress into refrigeration systems from tanks/

containers cause malfunctions.

3.5

Handling refrigerants

Note

♦ Refrigeranhas no perceptible odour and usually remains un‐

noticed.

♦ Refrigerangas is heavier than air. Icollects in low lying areas,

such as inspection pits, cellars and troughs or hollows, where

idisplaces the ambienair along with the oxygen. Spending

time in areas starved of oxygen can be fatal.

♦ If liquid refrigeranescapes e.g. from a leak, ivaporises aan

ambienpressure of abou1 bar aapprox. -29.4°C. If refrig‐

eranvaporises on the skin, the resulwill be frosbite or freeze

burns. Sensitive body parts, such as the cornea and mucous

membranes, are especially arisk. Larger freeze burns could

lead to loss of life.

♦ Refrigerangas is inflammable: electrostatic discharge, sparks

from striking tools, hosurfaces and naked flames could ignite

a mixture of R1234yf refrigeranand ambienair. However,

refrigeranonly burns if supported by a flame, or if iis in the

vicinity of a hosurface. Iextinguishes when iis no longer

supported e.g. by a flame.

♦ Refrigerandecomposes when exposed to a flame or in con‐

tacwith a hosurface. Danger of poisoning on inhaling poi‐

sonous decomposed products. A pungenodour indicates tha

the products of decomposition are already present. Breathing

in these substances musbe avoided in all circumstances, or

the bronchial tubes, lungs and other organs could be injured.

♦ The specific risks of refrigerant, material data etc. can be

gleaned from the safety data sheets. Safety data sheets abou

refrigerant, refrigeranoil etc. can be found on the ⇒ VW

ServiceNe.

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•

Do noweld, 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 thaparts of

the air conditioning system may heaup. When spray painting

is carried out, temperatures of objects in the drying booth or

the preheating zone musnoexceed 80°C.

Reason:

Heating causes greaexcess pressure to develop in the system,

which can cause the pressure release valve of the system to

open.

Remedy:

– Empty refrigerancircuiwith air conditioner service station

⇒ page 129 .

Note

Do norepair damaged or leaking parts of the air conditioner by

welding or soldering. These musbe renewed.

Refrigerancontainers (e.g. charging cylinders of air conditioner

service station ) musnever be subjected to excessive heaor

exposed to direcsunlight.

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Air conditioning systems with refrigeranR1234yf - General information - Edition 07.2017

Reason:

Refrigeranexpands as iheats up.

Remedy:

– When charging and storing compressed gas containers (re‐

turnable cylinders, recycling cylinders etc.), observe the ap‐

plicable regulations, technical rules and legislation.

– Containers musnever be completely filled with liquid refrig‐

erant. Withousufficienexpansion space (gas cushion), the

container will bursshould the temperature rise with devastat‐

ing consequences ⇒ “6.2 Physical properties”, page 19 .

Under no circumstances may refri_lg_keranbe charged into systems

or vessels containing air.

Remedy:

– Evacuate systems and containers before charging with refrig‐

eran⇒ page 129 .

3. Repair notes

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Technical data Repair notes for Your Volkswagen Sharan VAN Second Generation (2010-2023)

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