Get Air conditioning system -> 1.5.2 Renewing leaking or damaged components of empty refrigerant circuit 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

1.4.4

Detecting leaks in a vacuum test using

air conditioner service station , or in a

pressure test

All vehicles

CAUTION

Risk of freezing injury caused by escaping pressurised refrig‐

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 refrigerant and open the refrigerant circuit immedi‐

ately afterwards.

– If more than 10 minutes have passed since the refrigerant

was extracted, repeat the extraction process before opening

the refrigerant circuit. Pressure could build up in the refrig‐

erant circuit from continued evaporation.

– Switch off ignition.

♦ Detecting leaks in a vacuum test using air conditioner service

station , or in a pressure test

⇒ “2.5 Evacuating refrigerant circuit”, page 140

Note

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

erant loss per year) cannot usually be found by means of the

vacuum test or pressure test. The amount of air entering the

system or the nitrogen-air escaping it is too low to detect the

faulty area through noise.

♦ It is also not always possible to detect leaks in the refrigerant

circuit with more than 100 g refrigerant loss per year by means

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

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

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

could be too low to generate a noise that would be noticeable

in the faulty area.

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

refrigerant loss 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 test or pressure test

⇒ “2.5 Evacuating refrigerant circuit”, page 140 .

– Perform vacuum or pressure test ⇒ page 143 .

1.4.5

Detecting leaks in a pressure test (with

nitrogen or compressed air)

♦ Perform a vacuum test using the air conditioner service station

to see if any leaks can be found

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

be detected but not the exact location of the leak, an additional

pressure test can be performed using nitrogen or compressed

air ⇒ page 143

1. Refrigerant circuit

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

Note

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

erant loss per year) cannot usually be found by means of the

vacuum test or pressure test. The amount of air entering the

system or the nitrogen-air escaping it is too low to detect the

faulty area through noise.

♦ It is also not always possible to detect leaks in the refrigerant

circuit with more than 100 g refrigerant loss per year by means

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

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

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

could be too low to generate a noise that would be noticeable

in the faulty area.

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

refrigerant loss 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 test or pressure test

⇒ “2.5 Evacuating refrigerant circuit”, page 140 .

♦ A larger leak in the refrigerant circuit can be detected, for ex‐

ample, by pressurising the circuit to a maximum of 15 bar using

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

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

sound as the gas escapes.

Tools required:

Rep. gr.87 - Air conditioning system

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

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

adapter from your air conditioner service station and use it for

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 (cut off), 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 element for compressed air system with

an oil, dirt and water separator (to ensure that the refrigerant

circuit is pressurised with compressed air that is clean, dry and

free of oil) for the leakage test with 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 test with

nitrogen

– Perform pressure test ⇒ page 143 .

1.5

Renewing components

⇒ “1.5.1 General information about renewing components”, page

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

frigerant circuit (apart from air conditioner compressor and re‐

ceiver)”, page 81

⇒ “1.5.3 Renewing leaking or damaged components of charged

refrigerant circuit (apart from air conditioner compressor and re‐

ceiver)”, page 84

⇒ “1.5.4 Renewing air conditioner compressor with no need to

clean refrigerant circuit”, page 85 .

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

ternal damage”, page 87

⇒ “1.5.6 Renewing desiccant cartridge / receiver after cleaning

refrigerant circuit”, page 88

⇒ “1.5.7 Renewing receiver with no need to clean refrigerant cir‐

cuit”, page 90 .

⇒ “1.5.8 Renewing desiccant cartridge / desiccant bag with no

need to clean refrigerant circuit”, page 91

1.5.1

General information about renewing

components

The receiver or desiccant cartridge need not be renewed under

the following circumstances:

♦ The opened refrigerant circuit is sealed immediately with clean

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

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

er.

♦ Repairs are performed quickly (not for longer than the normal

repair time).

♦ The vehicle is no more than 5 years old.

1. Refrigerant circuit

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

The receiver or dryer cartridge should be renewed under the fol‐

lowing circumstances:

♦ The refrigerant circuit has been opened for an indeterminate

period (seepage leak).

♦ The receiver is damaged (e.g. in an accident).

♦ Repairs are performed over a longer time than the normal re‐

pair time.

♦ The refrigerant circuit was opened and the vehicle is more than

5 years old.

♦ The refrigerant circuit has been blown through with nitrogen.

♦ The refrigerant circuit has been flushed with R1234yf.

♦ The air conditioner compressor seizes.

•

All components of the refrigerant circuit that were submitted to

quality monitoring must be sealed (use the original sealing

caps from the replacement part).

•

Renew damaged or leaky components of the refrigerant circuit

⇒ page 79 .

All components of the refrigerant circuit that were submitted to

quality monitoring must be sealed (use the original sealing

caps from the replacement part).

•

The replacement air conditioner compressor, receiver, evap‐

orator and condenser were previously charged with nitrogen.

This filling is being gradually discontinued, or 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) .

The air conditioner compressor with air conditioner compres‐

sor regulating valve - N280- (without air conditioning system

magnetic clutch - N25- ) is switched to internal lubrication in

the event of an empty refrigerant circuit, in which case only a

small amount of oil is pumped from the air conditioner com‐

pressor into the circuit.

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Air conditioning system -> 1.5.2 Renewing leaking or damaged components of empty refrigerant circuit for Your Volkswagen Touran 4 Door Second Generation (2015-2022)

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