Get Air conditioning system -> 1.3 Possible complaints Guide for Volkswagen Touran 4 Door Second Generation (2015-2022)

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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017

♦ The refrigerant temperature sender (with temperature-de‐

pendent resistor) is installed e.g. in the high pressure line in

the vicinity of the air conditioner compressor.

♦ There is a direct correlation between temperature and pres‐

sure in the refrigerant circuit: if there is too little refrigerant in

the refrigerant circuit, the temperature in the refrigerant circuit

rises during operation of the air conditioning system on the

high pressure side greater than permitted for this pressure.

Note

The respective control unit, e.g. the operating and display unit for

front air conditioning system - E87- or the Climatronic control unit

- J255- evaluates the pressure and the temperature in the refrig‐

erant circuit and switches off the air conditioner compressor if the

temperature increases above the value stored for this pressure

⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode - air

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

87 ; Refrigerant circuit (vehicle-specific workshop manual).

1.3

Possible complaints

⇒ “1.3.1 Prerequisites for investigating a complaint”, page 64

⇒ “1.3.2 Possible complaints”, page 64

⇒ “1.3.3 Odours from heater and air conditioner unit”, page 66

1.3.1

Prerequisites for investigating a com‐

plaint

•

No fault was evident during fault finding in the electrical sys‐

tem, vacuum system and air ducts/channels ⇒ Vehicle diag‐

nostic tester in “Guided Fault Finding” mode - air conditioning

system (and battery control), ⇒ Current flow diagrams, Elec‐

trical fault finding and Fitting locations and ⇒ Heating, air

conditioning; Rep. gr. 00 ; Repair instructions; Checking cool‐

ing output .

•

Self-diagnosis in “Guided Fault Finding” mode - air condition‐

ing system (e.g. using ⇒ Vehicle diagnostic tester in “Guided

Fault Finding” mode - air conditioning system) provides no

evidence of a complaint.

No shut-off condition for the air conditioner compressor is dis‐

played in the measured values of the control unit of the air

conditioning system ⇒ Vehicle diagnostic tester in “Guided

Fault Finding” mode - air conditioning system.

1.3.2

Possible complaints

Note

♦ For all complaints marked with *

⇒ “2.14 Checking pressures”, page 170 .

♦ If on vehicles with 2 evaporators a problem is encountered in

just one evaporator, check the pressures in the refrigerant cir‐

cuit as well ⇒ “2.14 Checking pressures”, page 170 .

♦ The cooling has failed completely.*

♦ Insufficient cooling output at all vehicle speeds and engine

speeds.*

♦ No or insufficient cooling after driving a few miles. *

Rep. gr.87 - Air conditioning system

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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017

♦ No cooling or insufficient cooling from one or two evaporators

(on vehicles with 2nd heater and air conditioner/evaporators).

♦ Actuation of the air conditioner compressor (via the air condi‐

tioning system magnetic clutch - N25- or the air conditioner

compressor regulating valve - N280- ) is switched off by the

respective control unit (e.g. the operating and display unit for

front air conditioning system - E87- , the air conditioning sys‐

tem control unit - J301- or the Climatronic control unit - J255- )

due to pressure in the refrigerant circuit being too high or too

low * ⇒ Vehicle diagnostic tester in “Guided Fault Finding”

mode - air conditioning system.

♦ The electrical air conditioner compressor - V470- is not actu‐

ated by the control unit for air conditioning compressor - J842-

due to pressure being too high or too low * ⇒ Vehicle diagnostic

tester in “Guided Fault Finding” mode - air conditioning system

and battery regulation.

♦ If fresh air supply is lacking or drops significantly after a few

miles (evaporator iced up) *⇒ Vehicle diagnostic tester in “Gui‐

ded Fault Finding” mode - air conditioning system.

In addition, the following problems may occur:

The air conditioner compressor is noisy.

– Re-tighten the securing bolts for the air conditioner compres‐

sor and the air conditioner compressor bracket using a torque

wrench ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant

circuit; System overview - refrigerant circuit .

– Check the routing of the refrigerant lines. These must not rest

against other components and must not be under any strain

(realign them if necessary) ⇒ Heating, air conditioning; Rep.

gr. 87 ; Refrigerant circuit; System overview - refrigerant cir‐

cuit .

Noises (refrigerant hammering) occur immediately after the air

conditioning is switched on and/or in a curve or when the brakes

are applied:

– Drain the refrigerant circuit, evacuate it and recharge (too

much refrigerant or refrigerant oil in the circuit) ⇒ page 129

and ⇒ “2.14 Checking pressures”, page 170 .

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 con‐

ditioner compressor was renewed) ⇒ page 79 .

Water sprays out of the vents (in dash panel or footwell) although

air conditioning system is otherwise functioning properly:

– Check condensation drain to ensure that it is routed correctly.

It should not be kinked or crushed ⇒ Heating, air conditioning;

Rep. gr. 87 ; Front heater and air conditioner .

– The condensed water drain valve must not be hindered in its

operation by wax or underbody sealant and must open and

close properly ⇒ Heating, air conditioning; Rep. gr. 87 ; Front

heater and air conditioner .

– Check plenum chamber cover. It must not be damaged and

must be installed correctly (no water should run into the evap‐

orator) ⇒ Heating, air conditioning; Rep. gr. 87 ; Overview of

fitting locations - air conditioning system; Overview of fitting

locations - components outside passenger compartment .

1. Refrigerant circuit

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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017

– Check water drainage points of plenum chamber. These

should not be blocked (e.g. by leaves) ⇒ Heating, air condi‐

tioning; Rep. gr. 87 ; Overview of fitting locations - air condi‐

tioning system; Overview of fitting locations - components

outside passenger compartment .

Note

Installation location and other information about these compo‐

nents ⇒ Heating, air conditioning; Rep. gr. 87 ; Overview of fitting

locations - air conditioning system .

1.3.3

Odours from heater and air conditioner

unit

⇒ page 66

⇒ page 67

Does the odour emanate from the evaporator or 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 too “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

– Caused by accumulation of debris, pine needles etc. in plenum

chamber

Note

Clean the plenum chamber.

– Stagnant water that cannot flow out of plenum chamber.

Note

Check the water drainage points in the plenum chamber.

♦ Smell from heater and air conditioner unit

Note

Smells that originate from the heater and air conditioner unit can

be detected in fresh air mode and in recirculation mode.

Rep. gr.87 - Air conditioning system

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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017

– Due to too much condensate in the heater and air conditioner

unit

Note

Check the condensation drain.

– Due to an old or very dirty dust and pollen filter

Note

Check the dust and pollen filter.

– Due to deposits on the fins of the evaporator

Note

Clean the evaporator with the ultrasonic air conditioner cleaning

unit ⇒ page 67 or suction feed spray-gun and corresponding

spray lance ⇒ page 67 .

Ultrasonic air conditioner cleaning unit

– The ultrasonic air conditioner cleaning unit 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 ⇒ Electronic parts catalogue .

Spraying the evaporator with the suction feed spray-gun and

spray lance

Directly spray the evaporator with cleaning solution using a spray

lance (approx. 10 bar). The cleaning solution neutralises mi‐

crobes and bacteria directly on the evaporator.

To enable access to the evaporator, preparatory measures and

different spray lances are required.

Vehicle-specific operating instructions are provided with the

evaporator cleaning solution ⇒ Electronic parts catalogue .

1. Refrigerant circuit

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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017

1.4

Investigating leaks

⇒ “1.4.1 General information about investigating leaks in the re‐

frigerant circuit”, page 68

⇒ “1.4.2 Searching for leaks in refrigerant circuits using an elec‐

tronic leak detector”, page 69

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

⇒ “1.4.4 Detecting leaks in a vacuum test using air conditioner

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

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

pressed air)”, page 77

1.4.1

General information about investigating

leaks in the refrigerant circuit

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

refrigerant circuits. These procedures have been tested and

lead to a reliable result under the different usage conditions if

they are performed correctly and in accordance with the spe‐

cific complaint.

♦ Various methods are offered in the open market with which

leaks in refrigerant circuits can be traced. These methods are

not able to provide clear results in all cases and, unless the

exact procedure is adhered to, they can also result in various

components of the refrigerant circuit being identified as having

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

es can cause preliminary or permanent damage to the com‐

ponents of the refrigerant circuit

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

They must be renewed instead.

♦ 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

⇒ “2.5 Evacuating refrigerant circuit”, page 140 .

Rep. gr.87 - Air conditioning system

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Air conditioning system -> 1.3 Possible complaints for Your Volkswagen Touran 4 Door Second Generation (2015-2022)

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