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2015-2022 Volkswagen Touran 4 Door Air conditioning system -> 1.6 Cleaning refrigerant circuit User Manual

MY CAR USER MANUAL

Air conditioning system -> 1.6 Cleaning refrigerant circuit for Your Volkswagen Touran 4 Door Second Generation (2015-2022)

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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
Note  
♦ In the event of internal damage (to the air conditioner com‐  
pressor), check the refrigerant hoses and condenser. If con‐  
taminated by swarf, for example, clean ltkhe refrigerant hoses  
and condenser (flush with R1234yf refrigerant  
⇒ “1.6 Cleaning refrigerant circuit”, page 92 ); renew refrig‐  
erant hoses if necessary.  
♦ On certain vehicles (e.g. vehicles with 2 evaporators), the vol‐  
ume of refrigerant oil in the refrigerant circuit may be greater  
than the volume in the replacement air conditioner compres‐  
sor. Replenish the refrigerant circuit on these vehicles with the  
amount of refrigerant oil necessary ⇒ Heating, air condition‐  
ing; Rep. gr. 00 ; Technical data (vehicle-specific workshop  
manual).  
♦ In the event of a fault in the electronics of an electrical air con‐  
ditioning compressor (e.g. control unit for air conditioning com‐  
pressor - J842- defective), the refrigerant circuit need not be  
flushed. In this case, the air conditioner compressor is to be  
renewed without there being a requirement to clean the re‐  
frigerant circuit  
⇒ “1.5.4 Renewing air conditioner compressor with no need to  
clean refrigerant circuit”, page 85  
– Renew desiccant bag/desiccant cartridge (reservoir/receiver)  
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;  
System overview - refrigerant circuit .  
– Check expansion valve for contamination or corrosion, renew  
if necessary ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐  
erant circuit; System overview - refrigerant circuit .  
– Assemble the refrigerant circuit, evacuate and charge  
⇒ page 129 .  
1.5.6  
Renewing desiccant cartridge / receiver  
after cleaning refrigerant circuit  
Note  
Installed in the receiver is usually a desiccant cartridge or desic‐  
cant bag (depending on the layout of the refrigerant circuit) ⇒  
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System  
overview - refrigerant circuit  
♦ Observe the general information about renewing components  
⇒ “1.5.1 General information about renewing components”,  
page 79  
Note  
Clean the refrigerant circuit. In other words, flush with R1234yf  
refrigerant ⇒ “1.6 Cleaning refrigerant circuit”, page 92 .  
For example due to moisture ingress (the refrigerant circuit was  
open for too long) or contamination  
– Drain refrigerant circuit ⇒ page 129 .  
– Remove air conditioner compressor ⇒ Heating, air condition‐  
ing; Rep. gr. 87 ; Air conditioner compressor .  
88  
Rep. gr.87 - Air conditioning system  
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– Rectify cause of fault ⇒ Heating, air conditioning; Rep. gr. 87 ;  
Refrigerant circuit; System overview - refrigerant circuit .  
– Clean refrigerant circuit (flush with R1234yf refrigerant)  
⇒ “1.6 Cleaning refrigerant circuit”, page 92 .  
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Electrical air conditioner compressor  
– Flush air conditioner compressor of old refrigerant oil  
⇒ “2.11 Cleaning electrical air conditioning compressor”, page  
155 .  
Mechanical air conditioner compressor  
– Remove oil drain plug from air conditioner compressor ⇒  
Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐  
pressor .  
Note  
Different versions of oil drain plug and corresponding seal, renew  
⇒ “1.5.2 Renewing leaking or damaged components of empty re‐  
frigerant circuit (apart from air conditioner compressor and re‐  
ceiver)”, page 81 , ⇒ Heating, air conditioning; Rep. gr. 87 ;  
Refrigerant circuit; System overview - refrigerant circuit (vehicle-  
specific workshop manual) and ⇒ Electronic parts catalogue .  
– To speed up draining of the refrigerant oil, rotate the shaft of  
the air conditioner compressor e.g. using the belt pulley or the  
magnetic clutch pulley ⇒ Heating, air conditioning; Rep. gr.  
87 ; Air conditioner compressor .  
– Pour out old refrigerant oil from air conditioner compressor  
⇒ “1.5.4 Renewing air conditioner compressor with no need to  
clean refrigerant circuit”, page 85 .  
Note  
Dispose of old refrigerant oil (observing local regulations) ⇒ VW /  
Audi ServiceNet .  
All air conditioner compressors  
– Check expansion valve for contamination or corrosion, renew  
if necessary ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrig‐  
erant circuit; System overview - refrigerant circuit .  
– Then fill the air conditioner compressor with new refrigerant oil  
by the same amount of refrigerant oil filled in the replacement  
air conditioner compressor (or by the specified amount of re‐  
frigerant oil if the vehicle is fitted with 2 evaporators) ⇒  
Heating, air conditioning; Rep. gr. 00 ; Technical data; Re‐  
frigerant oil .  
1. Refrigerant circuit  
89  
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Note  
♦ Different refrigerant oils and volumes for different air condi‐  
tioner compressors ⇒ Heating, air conditioning; Rep. gr. 00 ;  
Technical data (vehicle-specific workshop manual).  
♦ To ensure proper lubrication of the air conditioner compressor  
when it runs for the first time, the air conditioner compressor  
must be filled with at least 40 cm3 of refrigerant oil; the re‐  
mainder can be poured e.g. into a refrigerant line or the new  
reservoir/receiver/inner heat exchanger  
⇒ “1.5.1 General information about renewing components”,  
page 79 , ⇒ Heating, air conditioning; Rep. gr. 00 ; Technical  
data .  
♦ If dirt enters the air conditioner compressor while the refriger‐  
ant circuit is open (e.g. after an accident), the refrigerant circuit  
must be cleaned and the air conditioner compressor renewed  
⇒ “1.6 Cleaning refrigerant circuit”, page 92 and ⇒ Heating,  
air conditioning; Rep. gr. 87 ; Air conditioner compressor .  
♦ On vehicles with 2 evaporators, the volume of refrigerant oil in  
the refrigerant circuit may be greater than the volume in the  
replacement air conditioner compressor. Replenish the refrig‐  
erant circuit with the amount of refrigerant oil necessary ⇒  
Heating, air conditioning; Rep. gr. 00 ; Technical data (vehicle-  
specific workshop manual).  
lk  
– Renew desiccant bag/desiccant cartridge (receiver) ⇒ Heat‐  
ing, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System  
overview - refrigerant circuit .  
– Assemble the refrigerant circuit, evacuate and charge  
⇒ page 129 .  
1.5.7  
Renewing receiver with no need to clean  
refrigerant circuit  
Note  
Installed in the receiver is usually a desiccant cartridge or desic‐  
cant bag (depending on the layout of the refrigerant circuit) ⇒  
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System  
overview - refrigerant circuit  
♦ Observe the general information about renewing components  
⇒ “1.5.1 General information about renewing components”,  
page 79  
Note  
Clean the refrigerant circuit. In other words, flush with R1234yf  
refrigerant ⇒ “1.6 Cleaning refrigerant circuit”, page 92 .  
♦ For example, refrigerant has leaked out but no dirt has entered  
the circuit.  
♦ If the gas analysis shows that contaminated refrigerant was in  
the circuit but there appears to be no problem with the function  
of the air conditioning system  
⇒ “2.3 Performing gas analysis of refrigerant”, page 134  
– Drain refrigerant circuit ⇒ page 129 .  
90  
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– Remove receiver ⇒ Heating, air conditioning; Rep. gr. 87 ;  
Refrigerant circuit; System overview - refrigerant circuit .  
– Remove dirt from receiver.  
lk  
– Weigh removed receiver.  
– Fill enough refrigerant oil into the new receiver so that it has  
the same weight as the item that was removed.  
– Install new receiver ⇒ Heating, air conditioning; Rep. gr. 87 ;  
Refrigerant circuit; System overview - refrigerant circuit .  
– Assemble the refrigerant circuit, evacuate and charge  
⇒ page 129 .  
1.5.8  
Renewing desiccant cartridge / desic‐  
cant bag with no need to clean refriger‐  
ant circuit  
Note  
Desiccant cartridges or desiccant bags are usually installed de‐  
pending on the layout of the refrigerant circuit ⇒ Heating, air  
conditioning; Rep. gr. 87 ; Refrigerant circuit; System overview -  
refrigerant circuit  
♦ Observe the general information about renewing components  
⇒ “1.5.1 General information about renewing components”,  
page 79  
Note  
Clean the refrigerant circuit. In other words, flush with R1234yf  
refrigerant ⇒ “1.6 Cleaning refrigerant circuit”, page 92 .  
♦ For example, refrigerant has leaked out but no dirt has entered  
the circuit.  
♦ If the gas analysis shows that contaminated refrigerant was in  
the circuit but there appears to be no problem with the function  
of the air conditioning system  
⇒ “2.3 Performing gas analysis of refrigerant”, page 134  
– Drain refrigerant circuit ⇒ page 129 .  
– Renew desiccant cartridge/desiccant bag ⇒ Heating, air con‐  
ditioning; Rep. gr. 87 ; Refrigerant circuit; System overview -  
refrigerant circuit (vehicle-specific workshop manual).  
Note  
If the desiccant cartridge/desiccant bag is permanently installed  
in a component (e.g. in the receiver on the condenser) and cannot  
be renewed individually, renew the receiver or condenser ⇒  
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System  
overview - refrigerant circuit .  
– Assemble the refrigerant circuit, evacuate and charge  
⇒ page 129 .  
1. Refrigerant circuit  
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1.6  
Cleaning refrigerant circuit  
⇒ “1.6.1 General information about cleaning refrigerant circuit”,  
page 92  
⇒ “1.6.2 Preparations for cleaning refrigerant circuit (flushing with  
R1234yf refrigerant)”, page 94  
⇒ “1.6.3 Refrigerant circuit cleaning procedure”, page 96  
⇒ “1.6.4 Principle circuit diagrams for cleaning (flushing circuits)  
- refrigerant circuit with expansion valve and receiver”,  
page 97  
⇒ “1.6.5 Principle circuit diagrams for cleaning (flushing circuits)  
- refrigerant circuit with restrictor and receiver (without high-volt‐  
age system)”, page 102  
⇒ “1.6.6 Principle circuit diagrams for cleaning (flushing circuits)  
- vehicles with high-voltage system (without auxiliary air condi‐  
tioning functions)”, page 105  
⇒ “1.6.7 Principle circuit diagrams for cleaning (flushing circuits)  
- vehicles with high-voltage system (with auxiliary air conditioning  
functions, e.g. heat pump mode)”, page 105  
⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105  
⇒ “1.6.9 General information about blowing through with com‐  
pressed air or nitrogen”, page 120  
⇒ “1.6.10 Blowing through refrigerant circuit with compressed air  
or nitrogen”, page 124  
1.6.1  
General information about cleaning re‐  
frigerant circuit  
Note  
♦ Work on the refrigerant circuit that involves the air conditioner  
service station can usually be carried out without the need to  
de-energise the high-voltage system.  
♦ Since certain components have to be removed to clean (flush)  
the refrigerant circuit, the high-voltage system must be de-  
energised before work commences ⇒ Electrical system -  
hybrid; Rep. gr. 93 ; Electric drive; General warning notices  
for work on high-voltage system .  
♦ If there is reason to believe that chemical substances (leak  
stop additives) have been poured in the refrigerant circuit (that  
is be flushed) to seal leaks, do not connect your air conditioner  
service station to this refrigerant circuit and do not flush this  
refrigerant circuit.  
♦ Chemical substances (leak stop additives) used to seal leaks  
form deposits in the refrigerant circuit. These can impair the  
function of the air conditioning system and cause the air con‐  
ditioning system (and your air conditioner service station) to  
fail.  
♦ Bring the customer's attention to the presence of substances  
in the air conditioning system that are not approved by Volks‐  
wagen/Audi, which prevent the air conditioning system from  
being flushed and repaired.  
92  
Rep. gr.87 - Air conditioning system  
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All vehicles  
Note  
♦ VW/Volkswagen/Audi does not endorse the use of chemical  
substances (leak inhibitor additives) for purposes of sealing  
leaks in refrigerant circuits.  
♦ These chemical substances (leak stop additives) react mostly  
with the ambient air or the humidity to stop leaks in the refrig‐  
erant circuit. They cause deposits to build up in the refrigerant  
circuit (and your air conditioner service station ), cause valves  
to malfunction and defects in other components with which  
they come into contact. These deposits cannot be completely  
removed from the components again (not even by flushing).  
The refrigerant circuit can only be repaired by replacing all  
components that have come into contact with this substance.  
♦ There are often no external signs to suggest that chemical  
substances (leak stop additives) have been used to seal leaks  
in a refrigerant circuit. Often, the stickers provided to mark  
such systems are missing. Therefore, exercise caution on ve‐  
hicles for which you have no service or repair record.  
♦ If there is no suitable air conditioner service station available  
for the R1234yf refrigerant, the air conditioner service station  
designed for R134a refrigerant may also be used and the re‐  
frigerant circuit may also be flushed with R134a refrigerant.  
Using R134a refrigerant to clean the refrigerant circuit is cur‐  
rently permissible ⇒ Air conditioning system with R134a re‐  
frigerant; Rep. gr. 87 ; General information about the air  
conditioning system and refrigerant circuit .  
♦ If during the gas analysis it is found that R1234yf refrigerant  
has been contaminated with a different gas, it must be extrac‐  
ted from the refrigerant circuit and disposed of as a gas of  
unknown composition in accordance with the relevant legisla‐  
tion ⇒ VW / Audi-ServiceNet and  
⇒ “2.13 Filling contaminated refrigerant in a recycling cylinder  
for analysis, processing or disposal”, page 161 .  
♦ Contaminated refrigerant can cause decomposition products  
to form and accumulate in the refrigerant circuit. These cannot  
be extracted with the refrigerant. The contaminated refrigerant  
oil, in this case, must be removed from the refrigerant circuit  
by flushing with refrigerant.  
•
To work as cleanly as possible, without being wasteful of the  
refrigerant, without complex assembly work and in an envi‐  
ronmentally friendly manner when removing moisture, con‐  
taminants (e.g. friction dust and particles from the defective air  
conditioner compressor) and old refrigerant oil, the refrigerant  
circuit must be flushed (using R1234yf refrigerant).  
The refrigerant circuit must be cleaned (flushed) with refrigerant  
R1234yf:  
– If dirt or other contamination is in the circuit.  
– The search for faults in the electrical system, the vacuum sys‐  
tem and the air ducts did not turn up any fault.(Moisture is in  
the refrigerant circuit and builds up pressure.)  
– If the refrigerant circuit has been left open for longer than nor‐  
mally required for repairs (e.g. following an accident).  
– Pressure and temperature measurements in the circuit indi‐  
cate that there is moisture in the refrigerant circuit.  
– There is doubt about the amount of refrigerant oil in the refrig‐  
erant circuit.  
1. Refrigerant circuit  
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– Under certain circumstances if contaminated R1234yf refrig‐  
erant was charged in the refrigerant circuit  
⇒ “1.5 Renewing components”, page 79 and  
⇒ “2.3 Performing gas analysis of refrigerant”, page 134  
Note  
If contaminated refrigerant is found and components of the re‐  
frigerant circuit exhibit signs of internal damage (e.g. corrosion on  
the inside of the refrigerant lines or breakdown of the inner layer  
of refrigerant hoses), flushing the refrigerant circuit may not be  
sufficient. In this case, all of the components of the refrigerant  
circuit must be renewed (owing to a gas being charged that se‐  
verely damaged the components).  
– The air conditioner compressor has to be exchanged because  
of internal damage (e.g. noisy or lack of power)  
⇒ “1.5 Renewing components”, page 79 .  
– If it is required by the workshop manual for the specific vehicle  
following the renewal of certain components.  
Tools required  
♦ Air conditioner service station with flushing device (this air  
conditioner service station incorporates the auxiliary function  
“flushing refrigerant circuit” and the corresponding flushing  
device for refrigerant circuits ⇒ Electronic parts catalogue .  
♦ Adapter case for Volkswagen/Audi passenger vehicles  
⇒ page 105 and ⇒ Electronic parts catalogue .  
Note  
lk  
♦ If you do not have an air conditioner service station with flush‐  
ing device ⇒ Electronic parts catalogue in your workshop, it  
may be possible depending on the version of your air condi‐  
tioner service station to use the refrigerant circuit flushing  
device ⇒ Electronic parts catalogue to flush the refrigerant  
circuit. However, the flushing routine must be performed man‐  
ually ⇒ page 159 .  
♦ In adapter case passenger vehicle set there is also a filling  
hose with 5/8 -18 UNF connections and large inner diameter,  
short type (commercially available).  
1.6.2  
Preparations for cleaning refrigerant cir‐  
cuit (flushing with R1234yf refrigerant)  
– Drain refrigerant circuit  
⇒ “2.4 Emptying refrigerant circuit”, page 137 .  
– Remove air conditioner compressor ⇒ Heating, air condition‐  
ing; Rep. gr. 87 ; Refrigerant circuit; System overview -  
refrigerant circuit (vehicle-specific workshop manual).  
On vehicles with restrictor and reservoir  
– Remove restrictor (vehicle-specific) and join the lines together  
again ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant  
circuit; System overview - refrigerant circuit (vehicle-specific  
workshop manual).  
– Remove the reservoir (vehicle-specific) and join the lines to‐  
gether again (using an adapter and the charging hose from the  
adapter case for VW/Audi passenger vehicles )  
⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105  
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant cir‐  
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Rep. gr.87 - Air conditioning system  
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cuit; System overview - refrigerant circuit (vehicle-specific  
workshop manual).  
Note  
The reservoir could be flushed. However, due to its large interior  
volume it draws too much refrigerant and when this is extracted,  
the reservoir ices up too heavily. This causes the refrigerant to  
evaporate only very slowly, lengthening the extraction process  
too much as a result.  
On vehicles with expansion valve and receiver  
– If possible and necessary with this refrigerant circuit (see no‐  
tice), remove the receiver or remove the desiccant cartridge  
from the receiver (vehicle-specific) and join the lines together  
again (using an adapter and the charge hose from the adapter  
case for Volkswagen/Audi passenger vehicles )  
⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105  
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant cir‐  
cuit; System overview - refrigerant circuit (vehicle-specific  
workshop manual).  
Note  
♦ Depending on the design, the receiver can be flushed (if nec‐  
essary, remove dryer cartridge installed in receiver)  
⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105  
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant cir‐  
cuit; System overview - refrigerant circuit (vehicle-specific  
workshop manual).  
♦ If the receiver is attached to the condenser, it must not be re‐  
moved for flushing (its design makes it suitable for flushing,  
and it is only renewed after flushing)  
⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105  
lk  
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant cir‐  
cuit; System overview - refrigerant circuit (vehicle-specific  
workshop manual).  
♦ With condensers in which the receiver / desiccant cartridge are  
integrated and cannot be renewed individually or are not avail‐  
able as individual parts, the condenser is to be renewed after  
flushing. On these vehicles, the condenser in this case is to  
be renewed with the receiver ⇒ Heating, air conditioning; Rep.  
gr. 87 ; Refrigerant circuit; System overview - refrigerant cir‐  
cuit (vehicle-specific workshop manual) and ⇒ Electronic  
parts catalogue .  
♦ Depending on the version, receivers - in which the desiccant  
cartridge is to be renewed individually - may feature an addi‐  
tional filter element, which will need to be renewed with the  
desiccant cartridge if necessary.  
– On vehicles with a dryer cartridge in the receiver on the con‐  
denser (vehicle-specific), remove the dryer cartridge and seal  
the opening on the receiver again ⇒ Heating, air conditioning;  
Rep. gr. 87 ; Refrigerant circuit; System overview - refrigerant  
circuit (vehicle-specific workshop manual).  
– Remove expansion valve (vehicle-specific) and fit an adapter  
from the adapter case for Volkswagen/Audi passenger vehi‐  
cles in its place  
⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105  
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant cir‐  
cuit; System overview - refrigerant circuit (vehicle-specific  
workshop manual).  
1. Refrigerant circuit  
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Note  
If there is not a suitable adapter for the expansion valve in the  
adapter case Volkswagen/Audi passenger vehicle set , the re‐  
moved expansion valve can also be drilled out (the old expansion  
valve has to be replaced in most cases anyway and is no longer  
required).  
– The sealing surfaces of the expansion valve must not be dam‐  
aged. If damage is caused to the sealing surfaces, refrigerant  
could escape.  
– Drill out expansion valve.  
Note  
♦ Before drilling, remove the regulator element and drill out the  
expansion valve using e.g. a suitably sized drill bit (diameter  
of drill bit e.g. 6.0 mm).  
♦ Before drilling out, some parts may have to be removed from  
the expansion valve depending on the version.  
♦ There are different types of expansion valve with different de‐  
signs. For type -A-, parts -B-, -C- and -D- must be removed,  
for example. Separate component -D- and then part -E- (the  
regulating element). Then drill out the expansion valve in area  
-F- using a suitably sized drill bit.  
♦ On version -G-, parts -H-, -I- and -K-, for example, must be  
removed and then area -L- drilled out using a suitably sized  
lk  
drill bit.  
– Clean the drilled out expansion valve of swarf (metal particles).  
– Reinstall parts -B-, -C- and -D- on type -A- or part -H- on type  
-G-.  
Note  
On vehicles with 2 evaporators, separate the circuit to the second  
evaporator from the circuit of the first evaporator and flush it in a  
separate work step  
⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105 and  
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; Sys‐  
tem overview - refrigerant circuit (vehicle-specific workshop man‐  
ual).  
♦ Clean (flush) the refrigerant circuit  
⇒ “2.12 Cleaning refrigerant circuit”, page 157  
1.6.3  
Refrigerant circuit cleaning procedure  
Note  
The procedure runs automatically as per the program in the air  
conditioner service station ⇒ Operating instructions air condi‐  
tioner service station .  
♦ After switching on, the flushing circuit (refrigerant circuit with  
connecting hoses and flushing device for refrigerant circuits)  
is evacuated first and, in the process, the refrigerant circuit is  
checked for leaks (it may be necessary to proceed to the next  
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Rep. gr.87 - Air conditioning system  
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step manually depending on the version of air conditioning  
service station ).  
♦ Once the refrigerant circuit has been checked for leaks by  
means of evacuating, a certain amount of refrigerant is filled  
in the system to check the flushing/refrigerant circuit for correct  
assembly (pressure test).  
♦ After the pressure test, the refrigerant is extracted, the refrig‐  
erant circuit is evacuated again, if necessary, and the cleaning  
(flushing) process begins.  
♦ A predefined volume of refrigerant is charged in the refrigerant  
circuit via the high pressure side of the air conditioner service  
station (in the opposite direction of normal flow during air con‐  
ditioning system operation and therefore on the low pressure  
side of the vehicle's refrigerant circuit). Alternatively, refriger‐  
ant is charged continually (depending on the internal volume  
of the flushing circuit e.g. 3 kg) until the refrigerant circuit and  
the inspection windows of the flushing device for refrigerant  
circuits are completely full with liquid refrigerant (the system  
detects, e.g. over a certain period of time, when refrigerant  
ceases to flow depending on the version of air conditioner  
service station ).  
♦ Once the predetermined amount of refrigerant has been filled  
in the system, the heater, for example, of the flushing device  
for refrigerant circuits is switched on depending on the type of  
air conditioner service station and flushing device for refriger‐  
ant circuits (only if the refrigerant is extracted in gaseous form  
out of the flushing device for refrigerant circuits).  
♦ When the refrigerant has been extracted, the heater of the  
flushing device for refrigerant circuits is switched off (if fitted),  
the refrigerant circuit may have to be evacuated briefly again  
depending on the type, and following evacuation the refriger‐  
ant oil evacuated by the air conditioner service station out of  
the refrigerant circuit is separated of water.  
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♦ The procedure for charging with refrigerant, extracting (and  
evacuating) is carried out three times (that means a total of  
four times).  
♦ After extracting for the fourth time, the flushing circuit is evac‐  
uated depending on the type of air conditioner service station .  
1.6.4  
Principle circuit diagrams for cleaning  
(flushing circuits) - refrigerant circuit with  
expansion valve and receiver  
♦ With 1 or 2 evaporators  
♦ With and without high-voltage system  
1. Refrigerant circuit  
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Note  
♦ The arrows in the following illustrations show the direction of  
refrigerant flow during flushing (during flushing, the refrigerant  
flows against the direction of flow with normal air conditioning  
operation, which is why the high pressure side of the air con‐  
ditioner service station is connected on the low pressure con‐  
nection of the refrigerant circuit to the air conditioner  
compressor).  
♦ This principle circuit diagram shows a refrigerant circuit with  
expansion valve, receiver and a second evaporator (extra  
equipment on certain vehicles).  
♦ On vehicles with expansion valve and receiver, the expansion  
valve is removed and an adapter installed in its place. The  
receiver is also removed depending on the vehicle and the line  
connections to the receiver are joined together with 2 adapters  
and a filling hose.  
♦ On vehicles with just one evaporator, the components from  
position “16” are not installed or not required.  
♦ Depending on the design of the air conditioner service station  
there may be non-return valves installed between the refrig‐  
lk  
erant circuit and the air conditioner service station (to assure  
the correct direction of refrigerant flow during flushing).  
♦ The adapters from the adapter case for VW/Audi passenger  
vehicles have a 5/8 -18 UNF thread. To ensure that the charge  
hoses of the R1234yf- air conditioner service station can be  
connected, additional adapters from the case are to be used  
adapter case for VW/Audi passenger vehicles ⇒ Electronic  
parts catalogue .  
♦ Installed in the refrigerant circuit on vehicles with a high-volt‐  
age system are electrically actuated valves that have to be  
removed for cleaning (flushing) and replaced with manual  
shut-off valves or adapters ⇒ Heating, air conditioning; Rep.  
gr. 87 ; Refrigerant circuit .  
98  
Rep. gr.87 - Air conditioning system  
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1 - Air conditioner service sta‐  
tion  
❑ With electronics and  
flushing program, air  
conditioner service sta‐  
tion with flushing device  
⇒ Electronic parts cata‐  
logue (Tools; Workshop  
equipment/tools; Air  
conditioning system/  
heating)  
❑ If an air conditioner  
service station without  
flushing program is  
used, the sequence has  
to be carried out man‐  
ually (evacuate, flush  
4 times with at least 3 kg  
of refrigerant each time  
and extract refrigerant  
again, evacuate).  
2 - Refrigerant hose of air con‐  
ditioner service station  
❑ From high pressure side  
of air conditioner service  
station (normally col‐  
oured red) for connect‐  
ing low pressure side of  
air conditioner compres‐  
sor to refrigerant circuit  
(larger diameter)  
3 - Adapter for connection to  
low pressure side in refrigerant  
circuit  
❑ Different versions de‐  
pending on vehicle  
⇒ “1.6.8 Adapters for  
setting up flushing cir‐  
cuits”, page 105  
❑ The item to be used between the refrigerant hose -2- and adapter -3- is adapter - VAS 6338/48- .  
❑ From adapter case VW/Audi passenger vehicle set  
❑ Depending on the version of adapter, an additional adapter is required here to connect the charge hose  
of the air conditioner service station  
Note  
♦ The charge hose of the air con‐  
ditioner service station has an  
M12 x 1.5-6G external thread in  
accordance with SAE J639. Lo‐  
cated on the adapter for connec‐  
tion of the low pressure side is a  
5/8 -18 UNF external thread. To  
ensure that both components  
can be connected together, an  
additional adapter is required ⇒  
Electronic parts catalogue  
(Tools; Workshop equipment/  
tools; Air conditioning system/  
heating).  
1. Refrigerant circuit  
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♦ To attain the fastest flow speed  
possible, the service coupling is  
removed from the charge hose  
for purposes of flushing (bottle-  
necks are present in the service  
coupling that would significantly  
reduce the flow speed).  
4 - Connection of low pressure side in refrigerant circuit  
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105  
5 - Adapter for removed expansion valve  
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105  
❑ From adapter case for VW/Audi passenger vehicles ⇒ Electronic parts catalogue (Tools; Workshop  
equipment/tools; Air conditioning/heating)  
6 - Evaporator  
7 - Connection to receiver  
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105  
❑ Not fitted in vehicles with a dryer cartridge in the receiver on the condenser or with a receiver installed  
in the condenser ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System overview - refrig‐  
erant circuit (vehicle-specific workshop manual).  
8 - Adapter for bridging removed receiver  
❑ Not required on all vehicles  
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105  
❑ From adapter case VW/Audi passenger vehicle set  
9 - Charge hose for refrigerant  
❑ For example charge hose from adapter case VW/Audi for passenger vehicles  
⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105  
10 - Condenser  
❑ If a receiver with dryer cartridge is fitted at the condenser, the dryer cartridge must be removed (seal  
receiver at or in condenser again following removal) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant  
circuit; System overview - refrigerant circuit (vehicle-specific workshop manual).  
lk  
❑ If the receiver is attached directly to the condenser, flush the system before removing and renewing the  
receiver ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System overview - refrigerant circuit  
(vehicle-specific workshop manual).  
Note  
On certain vehicles, the receiver is  
integrated in the condenser and the  
desiccant cartridge cannot be re‐  
newed individually or is not availa‐  
ble individually as a replacement  
part. On these vehicles, the con‐  
denser in this case is to be renewed  
with the receiver ⇒ Heating, air con‐  
ditioning; Rep. gr. 87 ; Refrigerant  
circuit; System overview - refriger‐  
ant circuit and ⇒ Electronic parts  
catalogue .  
11 - Connection for high pressure side on refrigerant circuit  
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105  
12 - Adapter for connection of high pressure side in refrigerant circuit  
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105  
❑ From adapter case VW/Audi passenger vehicle set  
100  
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13 - Charging hose of flushing device for refrigerant circuits  
❑ From connection to high pressure side of air conditioner compressor on refrigerant circuit (smaller di‐  
ameter) to inlet of flushing device for refrigerant circuits.  
14 - Flushing device for refrigerant circuits  
❑ Different versions and different design of flushing devices for refrigerant circuits ⇒ Electronic parts cata‐  
logue (Tools; Workshop equipment/tools; Air conditioning/heating)  
❑ With filter, sight glass, safety valve, heating, refrigerant tank, etc. (depending on version).  
❑ Depending on the design of the air conditioner service station and the flushing device for refrigerant  
circuits, there may be a non-return valve installed at the outlet of the flushing device for refrigerant circuits  
(to assure the correct direction of refrigerant flow during flushing).  
❑ Depending on the flushing device there may be a 5/8 -18 UNF external thread, a connection for R134a  
or a R1234yf high pressure service coupling at the outlet to the air conditioner service station  
lk  
Note  
♦ To ensure that the flushing de‐  
vice can be connected to the air  
conditioner service station ,  
flushing devices with a 5/8 -18  
UNF external thread or a con‐  
nection for an R134a low pres‐  
sure service coupling require an  
additional adapter to facilitate  
connection of the R1234yf low  
pressure service coupling or the  
charge hose to the air condition‐  
er service station (with an M12 x  
1.5-6G external thread in ac‐  
cordance with SAE J639) at the  
outlet of the flushing device.  
♦ The charge hose of the air con‐  
ditioner service station has an  
M12 x 1.5-6G external thread in  
accordance with SAE J639. De‐  
pending on the type of service  
connection, there may be a low  
pressure service coupling in ac‐  
cordance with SAE J639 for the  
R1234yf refrigerant, an M12 x  
1.5-6G internal thread in accord‐  
ance with SAE J639, a service  
connection for an R134a low  
pressure service coupling or a  
5/8 - 18 UNF external thread on  
the flushing device for refrigerant  
circuits. To ensure that both  
components can be connected  
to each other, an additional  
adapter may be necessary ⇒  
Electronic parts catalogue .  
♦ Since refrigerant is only drawn in  
by the air conditioner service sta‐  
tion at a low flow speed, the low  
pressure service coupling can be  
used here.  
15 - Refrigerant hose of air conditioner service station  
❑ From the low pressure side of the air conditioner service station (normally coloured blue) to the outlet of  
the flushing device for refrigerant circuits.  
16 - Adapter to seal outlet to second evaporator  
❑ Only required on certain vehicles with “second evaporator” (optional equipment)  
❑ From adapter case VW/Audi passenger vehicle set  
1. Refrigerant circuit  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
17 - Adapter to seal outlet to second evaporator  
❑ Only required on certain vehicles with “second evaporator” (optional equipment)  
❑ From adapter case VW/Audi passenger vehicle set  
18 - Connection of low pressure side in refrigerant circuit to second evaporator  
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105  
❑ Only fitted on certain vehicles with “second evaporator” (optional equipment)  
19 - Connection of high pressure side on refrigerant circuit to second evaporator  
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105  
❑ Only fitted on certain vehicles with “second evaporator” (optional equipment)  
20 - Adapter for removed expansion valve on second evaporator  
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105  
❑ Only required on certain vehicles with “second evaporator” (optional equipment)  
❑ From adapter case VW/Audi passenger vehicle set  
21 - Second evaporator  
❑ Only fitted on certain vehicles with “second evaporator” (optional equipment)  
1.6.5  
Principle circuit diagrams for cleaning  
(flushing circuits) - refrigerant circuit with  
restrictor and receiver (without high-volt‐  
age system)  
Note  
♦ On vehicles with restrictor and reservoir, the restrictor and the  
reservoir must be removed. The lines that were detached to  
remove the restrictor are reinstalled. The line connections to  
the removed reservoir are joined together with 2 adapters and  
the charge hose (from the adapter case for VW/Audi passen‐  
ger vehicles ).  
♦ This layout with restrictor and refrigerant circuit reservoir is  
currently not used at Volkswagen/Audi.  
♦ The arrows in the following illustrations show the direction of  
refrigerant flow during flushing (during flushing, the refrigerant  
flows against the direction of flow with normal air conditioning  
operation, which is why the high pressure side of the air con‐  
ditioner service station is connected on the low pressure con‐  
nection of the refrigerant circuit to the air conditioner  
compressor).  
♦ Depending on the design of the air conditioner service station  
there may be non-return valves installed between the refrig‐  
erant circuit and the air conditioner service station (to assure  
the correct direction of refrigerant flow during flushing).  
♦ The adapters from the adapter case for VW/Audi passenger  
vehicles have a 5/8 -18 UNF thread. To ensure that the charge  
hoses of the R1234yf- air conditioner service station can be  
connected, additional adapters from the case are to be used  
adapter case for VW/Audi passenger vehicles .  
102  
Rep. gr.87 - Air conditioning system  
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1 - Air conditioner service sta‐  
tion  
❑ With electronics and  
flushing program, e.g.  
air conditioner service  
station with flushing de‐  
vice ⇒ Electronic parts  
catalogue (Tools; Work‐  
shop equipment/tools;  
Air conditioning/heat‐  
ing)  
❑ If an air conditioner  
service station without  
flushing program is  
used, the sequence has  
to be carried out man‐  
ually (evacuate, flush  
4 times with at least 3 kg  
of refrigerant each time  
and extract refrigerant  
again, evacuate).  
2 - Refrigerant hose of air con‐  
ditioner service station  
❑ From high pressure side  
of air conditioner service  
station (normally col‐  
oured red) for connect‐  
ing low pressure side of  
air conditioner compres‐  
sor to refrigerant circuit  
(larger diameter)  
3 - Adapter for connection to  
low pressure side in refrigerant  
circuit  
❑ Different versions de‐  
pending on vehicle  
⇒ “1.6.8 Adapters for  
setting up flushing cir‐  
cuits”, page 105  
❑ The item to be used between the refrigerant hose -2- and adapter -3- is adapter - VAS 6338/48- .  
❑ From adapter case VW/Audi passenger vehicle set  
Note  
♦ The charge hose of the air con‐  
ditioner service station has an  
M12 x 1.5-6G external thread in  
accordance with SAE J639. Lo‐  
cated on the adapter for connec‐  
tion of the low pressure side is a  
5/8 -18 UNF external thread. To  
ensure that both components  
can be connected to each other,  
an additional adapter is required  
⇒ Electronic parts catalogue .  
♦ To attain the fastest flow speed  
possible, the service coupling is  
removed from the charge hose  
for purposes of flushing (bottle-  
necks are present in the service  
coupling that would significantly  
reduce the flow speed).  
1. Refrigerant circuit  
103  
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4 - Connection of low pressure side in refrigerant circuit  
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105  
❑ On refrigerant line from air conditioner compressor to reservoir  
5 - Connection to reservoir  
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105  
❑ On refrigerant line from air conditioner compressor to reservoir  
6 - Adapter for bridging removed reservoir  
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105  
❑ From adapter case VW/Audi passenger vehicle set  
7 - Charge hose for refrigerant  
❑ For example charge hose from adapter case VW/Audi for passenger vehicles  
⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105  
8 - Adapter for bridging removed reservoir  
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105  
❑ From adapter case VW/Audi passenger vehicle set  
9 - Connection to reservoir  
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105  
10 - Evaporator  
11 - Location of restrictor  
❑ The restrictor is removed.  
❑ Remove restrictor ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System overview - re‐  
frigerant circuit (vehicle-specific workshop manual).  
12 - Threaded connection in refrigerant line  
❑ Screw back together following removal of the restrictor ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐  
frigerant circuit; System overview - refrigerant circuit (vehicle-specific workshop manual).  
13 - Condenser  
14 - Connection for high pressure side on refrigerant circuit  
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105  
15 - Adapter for connection of high pressure side in refrigerant circuit  
❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105  
❑ From adapter case VW/Audi passenger vehicle set  
16 - Charging hose of flushing device for refrigerant circuits  
❑ From connection to high pressure side of air conditioner compressor on refrigerant circuit (smaller di‐  
ameter) to inlet of flushing device for refrigerant circuits.  
17 - Flushing device for refrigerant circuits  
❑ Different versions and different design of flushing devices for refrigerant circuits ⇒ Electronic parts cata‐  
logue (Tools; Workshop equipment/tools; Air conditioning/heating)  
❑ With filter, sight glass, safety valve, heating, refrigerant tank, etc. (depending on version).  
❑ Depending on the design of the air conditioner service station and the flushing device for refrigerant  
circuits, there may be a non-return valve installed at the outlet of the flushing device for refrigerant circuits  
(to assure the correct direction of refrigerant flow during flushing).  
❑ Depending on the layout of the flushing device for refrigerant circuits, there may be a connection for a  
service coupling for refrigerant circuits at the outlet and possibly the inlet of the flushing device (instead  
of a 5/8-18 UNF external thread). If a service connection with a valve is installed at the outlet of the  
flushing device, this valve must be opened completely when the service coupling is connected (an in‐  
completely opened valve represents a bottle-neck). If a connection for a service coupling is present at  
the inlet of the flushing device, the inlet must be converted in such a way that the refrigerant hose coming  
from the vehicle can be connected directly (a service coupling and a valve in the inlet of the flushing  
device represent a bottle-neck that can hinder the flow of refrigerant out of the vehicle into the flushing  
device and thereby affect the flushing process).  
104  
Rep. gr.87 - Air conditioning system  
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18 - Refrigerant hose of air conditioner service station  
❑ From the low pressure side of the air conditioner service station (normally coloured blue) to the outlet of  
the flushing device for refrigerant circuits.  
1.6.6  
Principle circuit diagrams for cleaning  
(flushing circuits) - vehicles with high-  
voltage system (without auxiliary air  
conditioning functions)  
Note  
♦ The refrigerant circuit is cleaned in 2 flushing cycles (first the  
section with the evaporator in the front heating and air condi‐  
tioning unit and then the section with the heat exchanger for  
high-voltage battery or evaporator in the battery cooling mod‐  
ule) ⇒ page 105  
♦ On vehicles with 2 evaporators or an evaporator and heat ex‐  
changer, separate the circuit to the second evaporator or the  
heat exchanger from the circuit of the first evaporator via hand  
shut-off valves, and flush it in a separate work step  
⇒ page 105 and ⇒ Heating, air conditioning; Rep. gr. 87 ;  
Refrigerant circuit; System overview - refrigerant circuit (vehi‐  
cle-specific workshop manual).  
♦ The layout of the various flushing circuits for these vehicles is  
similar to that on a vehicle with 2 evaporators.  
lk  
1.6.7  
Principle circuit diagrams for cleaning  
(flushing circuits) - vehicles with high-  
voltage system (with auxiliary air condi‐  
tioning functions, e.g. heat pump mode)  
Note  
♦ The refrigerant circuit is cleaned in several flushing cycles  
⇒ page 105 and ⇒ Heating, air conditioning; Rep. gr. 87 ;  
Refrigerant circuit (cleaning refrigerant circuit of air condition‐  
ing system).  
♦ For flushing, the circuit is split into several sections and then  
flushed in one cleaning cycle respectively. The division is per‐  
formed by means of the integrated electric valves that are  
switched electrically and the manual shut-off valves that are  
switched manually ⇒ Heating, air conditioning; Rep. gr. 87 ;  
Refrigerant circuit (cleaning refrigerant circuit of air condition‐  
ing system).  
♦ The layout of the various flushing circuits for these vehicles is  
described in the relevant vehicle-specific workshop manual ⇒  
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit  
(cleaning refrigerant circuit of air conditioning system  
⇒ “1.6.4 Principle circuit diagrams for cleaning (flushing cir‐  
cuits) - refrigerant circuit with expansion valve and receiver”,  
page 97 ).  
1.6.8  
Adapters for setting up flushing circuits  
♦ The following table contains the various adapters that are nec‐  
essary to connect the air conditioner service station to the  
refrigerant circuit for purposes of flushing and to bridge the  
1. Refrigerant circuit  
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removed reservoir or receiver and expansion valve (vehicle-  
specific).  
♦ The adapters from the adapter case for VW/Audi passenger  
vehicles have a 5/8 -18 UNF thread. To ensure that the charge  
hoses of the R1234yf- air conditioner service station can be  
connected (M12 x 1.5-6G in accordance with SAE J639), ad‐  
ditional adapters from the case are to be used.  
♦ Using a charge hose with 5/8 -18 UNF connections (short ver‐  
sion, e.g. charge hose ), join both adapters, which were in‐  
stalled in place of the reservoir or receiver (included in adapter  
case for VW/Audi passenger vehicles ).  
♦ If a flushed refrigerant circuit is not going to be reassembled  
immediately after flushing, leave the adapters on the connec‐  
tions and seal the connections on the adapters using the  
lk  
sealing caps - VAS 6338/30- (from adapter case for VW/Audi  
passenger vehicles ).  
♦ Depending on the version of the air conditioner compressor  
and the production period, different connection and sealing  
methods may have been used for the refrigerant circuit ⇒  
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;  
System overview - refrigerant circuit (vehicle-specific work‐  
shop manual).  
Block or threaded connections  
– Threaded connection -A-  
– Block connection -B-  
Block connections with various types of seals  
– Block connection with radial sealing connection -A- (with guide  
made from plastic or metal -B-)  
– Block connection with axial sealing connection -C-.  
Assembling flushing circuit - passenger cars ⇒ page 106 or com‐  
mercial vehicles ⇒ page 107 .  
Passenger cars  
Assembling flushing circuit  
Arteon 2018 ▶  
Atlas 2017 ▶  
CC 2012 ▶  
e-Golf 2014 ▶, e-Golf 2014 ▶ with heat pump  
Golf 2013 ▶, Golf Estate 2014 ▶  
Golf 2015 ▶, Golf Estate 2015 ▶  
Golf GTE  
⇒ page 107  
⇒ page 108  
⇒ page 109  
⇒ page 109  
⇒ page 110  
⇒ page 110  
⇒ page 111  
⇒ page 113  
Golf Cabriolet 2012 ▶  
106  
Rep. gr.87 - Air conditioning system  
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Assembling flushing circuit  
Golf SV 2015 ▶  
Jetta 2015 ▶  
Jetta 2018 ▶  
Passat 2015 ▶, Passat Estate 2015 ▶  
Passat 2018 ▶, Passat Estate 2018 ▶  
Passat GTE  
Polo 2014 ▶  
Polo 2018 ▶  
⇒ page 110  
⇒ page 118  
⇒ page 118  
⇒ page 113  
⇒ page 113  
⇒ page 111  
⇒ page 114  
⇒ page 114  
⇒ page 113  
⇒ page 115  
Scirocco 2015 ▶  
Sharan 2016 ▶  
lk  
The Beetle 2017 ▶, The Beetle Cabriolet 2017 ▶  
The Beetle 2018 ▶, The Beetle Cabriolet 2018 ▶  
Tiguan 2016 ▶, Tiguan MEX 2017 ▶  
Touareg 2015 ▶  
Touran 2016 ▶  
up! 2017 ▶  
⇒ page 118  
⇒ page 118  
⇒ page 116  
⇒ page 116  
⇒ page 110  
⇒ page 117  
⇒ page 117  
e-up! 2017 ▶  
Commercial vehicles ⇒ page 107  
Note  
For a detailed description of assembling the flushing circuit, refer  
to the workshop manual ⇒ Air conditioning system with refrigerant  
R134a; Rep. gr. 00 ; Cleaning refrigerant circuit, commercial ve‐  
hicles .  
Assembling flushing circuit  
Caddy 2016 ▶  
Crafter 2017 or MAN TGE ▶  
Transporter 2016 ▶  
⇒ page 119  
⇒ page 119  
⇒ page 120  
Passenger cars  
Arteon 2018 ▶  
Vehicle  
Adapters required for refrigerant pipes Adapters required for re‐  
Miscellaneous  
to air conditioner compressor  
frigerant pipes to receiver  
Arteon 2018 ▶ ♦ Low-pressure side adapter - VAS  
6338/12-  
Remo–ve desiccant  
bag/cartridge and seal  
receiver.  
Install a–dapter - VAS  
6338/38- in place of ex‐  
pansion valve (or a dril‐  
led out expansion valve  
⇒ page 96 )  
♦ High pressure side adapter - VAS  
6338/3-  
After flu–shing, install a  
new desiccant bag/car‐  
tridge.  
♦ Adapter - VAS 6338/48- for air con‐  
ditioner service station  
After flu–shing, install a  
new expansion valve.  
1. Refrigerant circuit  
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Note  
On vehicles having condensers with an integrated receiver/des‐  
iccant cartridge which cannot be renewed separately or which is  
not available as a separate replacement part, the condenser must  
be renewed after flushing (together with integrated desiccant car‐  
tridge) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant  
circuit; System overview - refrigerant circuit and ⇒ Electronic  
parts catalogue .  
Atlas 2017 ▶  
Vehicle  
Adapters required for refrigerant pipes to Adapters required for re‐  
Miscellaneous  
air conditioner compressor  
frigerant pipes to receiver  
Atlas 2017 ▶ ♦ Low-pressure side adapter - VAS  
6338/12-  
Remo–ve desiccant  
bag/cartridge and seal  
receiver.  
Install a–dapter - VAS  
6338/38- in place of ex‐  
pansion valve (or a dril‐  
led out expansion valve  
⇒ page 96 )  
♦
High pressure side adapter - VAS  
After flu–shing, install a  
new desiccant bag/car‐  
tridge.  
lk  
6338/3-  
♦ Adapter - VAS 6338/48- for air con‐  
ditioner service station  
♦ Low-pressure line for  
second evaporator  
adapter - VAS 6338/3-  
After flu–shing, install a  
new expansion valve.  
♦ High-pressure line for  
second evaporator  
adapter - VAS  
6338/60-  
♦ The refrigerant lines to  
the second evaporator  
must be loosened suf‐  
ficiently so that the  
adapter can be fitted  
without deforming the  
refrigerant lines.  
♦ Low-pressure line for  
2nd evaporator, seal‐  
ing adapter - VAS  
6338/63- for front re‐  
frigerant circuit.  
♦ High-pressure line for  
2nd evaporator, seal‐  
ing adapter - VAS  
6338/5- for front refrig‐  
erant circuit.  
Note  
On vehicles having condensers with an integrated receiver/des‐  
iccant cartridge which cannot be renewed separately or which is  
not available as a separate replacement part, the condenser must  
be renewed after flushing (together with integrated desiccant car‐  
tridge) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant  
circuit; System overview - refrigerant circuit and ⇒ Electronic  
parts catalogue .  
108  
Rep. gr.87 - Air conditioning system  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
CC 2012 ▶  
Vehicle Adapters required for refrigerant pipes to Adapters required for re‐  
Miscellaneous  
air conditioner compressor  
frigerant pipes to receiver  
CC 2012 ▶ ♦ Low pressure side adapter - VAS  
6338/12- connected to air conditioner  
service station and adapter - VAS  
6338/48- .  
Remo–ve desiccant  
bag/cartridge and seal  
receiver.  
Install a–dapter - VAS  
6338/18- in place of ex‐  
pansion valve (or a dril‐  
led out expansion valve  
⇒ page 96 )  
After flu–shing, install a  
new desiccant bag/car‐  
tridge.  
♦
High pressure side adapter - VAS  
6338/3-  
After flu–shing, install a  
new expansion valve.  
If a Sho–wa condenser  
is fitted, leave the re‐  
ceiver fitted and flush  
the refrigerant circuit.  
After flu–shing, install a  
new receiver.  
Note  
On vehicles having condensers with an integrated receiver/des‐  
iccant cartridge which cannot be renewed separately or which is  
not available as a separate replacement part, the condenser must  
be renewed after flushing (together with integrated desiccant car‐  
tridge) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant  
circuit; System overview - refrigerant circuit and ⇒ Electronic  
parts catalogue .  
e-Golf 2014 ▶, e-Golf 2014 ▶ with heat pump  
Vehicle  
Adapters required for refriger‐ Adapters required for re‐  
Miscellaneous  
ant pipes to air conditioner frigerant pipes to receiver  
compressor  
e-Golf 2014 ►  
♦ Low pressure side adapter  
- VAS 6338/12- connected  
to air conditioner service  
station and adapter - VAS  
6338/48- .  
Remove–desiccant car‐  
tridge and seal receiv‐  
er.  
Install a–dapter - VAS  
6338/38- in place of ex‐  
pansion valve (or a dril‐  
led out expansion valve  
⇒ page 96 )  
After flu–shing, install a  
new dryer cartridge.  
♦ High pressure side adapter  
- VAS 6338/3-  
After flu–shing, install a  
new expansion valve.  
♦ Flushing electric air condi‐  
tioner compressor adapter  
- VAS 6338/40- and adapt‐  
er - VAS 6338/41- , see  
notes: ⇒ page 155  
e-Golf 2014 ► with  
heat pump  
♦ Low pressure side adapter  
- VAS 6338/12- connected  
to air conditioner service  
station and adapter - VAS  
6338/48- .  
Remove–reservoir (dry‐  
er), and bridge refriger‐  
ant pipes.  
Start “B–asic setting” in  
⇒ Vehicle diagnostic  
tester, and start the  
function “Charge refrig‐  
erant circuit”.  
Join tw–o adapters -  
VAS 6338/6- with hose ♦ This will open the elec‐  
♦ High pressure side adapter  
- VAS 6338/3-  
- VAS 6338/31- togeth‐  
er.  
trical valves in the re‐  
frigerant circuit.  
♦ Flushing electric air condi‐  
tioner compressor adapter  
- VAS 6338/40- and adapt‐  
er - VAS 6338/41- , see  
notes: ⇒ page 155  
♦ Leave vehicle diagnos‐  
tic tester connected to  
keep the valves open.  
After flu–shing, install a  
new reservoir.  
1. Refrigerant circuit  
109  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
lk  
Note  
On vehicles having condensers with an integrated receiver/des‐  
iccant cartridge which cannot be renewed separately or which is  
not available as a separate replacement part, the condenser must  
be renewed after flushing (together with integrated desiccant car‐  
tridge) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant  
circuit; System overview - refrigerant circuit and ⇒ Electronic  
parts catalogue .  
Golf 2013 ▶, Golf 2015 ▶, Golf Estate 2014 ▶, Golf Estate 2015  
▶, Golf SV 2015 ▶, Touran 2016 ▶  
Vehicle  
Adapters required for refriger‐ Adapters required for re‐  
Miscellaneous  
ant pipes to air conditioner frigerant pipes to receiver  
compressor  
Golf 2013 ▶, Golf 2015 ♦ Low pressure side adapter  
Remo–ve desiccant  
bag/cartridge and seal  
receiver.  
Install a–dapter - VAS  
6338/38- in place of ex‐  
pansion valve (or a dril‐  
led out expansion valve  
⇒ page 96 )  
▶, Golf Estate 2015 ▶,  
Golf Estate 2014 ▶,  
Golf SV 2015 ▶, Tour‐  
an 2016 ▶  
- VAS 6338/12- connected  
to air conditioner service  
station and adapter - VAS  
6338/48- .  
After flu–shing, install a  
new desiccant bag/car‐  
tridge.  
♦ High pressure side adapter  
- VAS 6338/3-  
After flu–shing, install a  
new expansion valve.  
If a cond–enser/receiver  
with permanently in‐  
stalled desiccant bag /  
cartridge is installed,  
leave the condenser/  
receiver in situ and  
flush the refrigerant cir‐  
cuit.  
After flu–shing, install a  
new receiver.  
Note  
On vehicles having condensers with an integrated receiver/des‐  
iccant cartridge which cannot be renewed separately or which is  
not available as a separate replacement part, the condenser must  
be renewed after flushing (together with integrated desiccant car‐  
tridge) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant  
circuit; System overview - refrigerant circuit and ⇒ Electronic  
parts catalogue .  
110  
Rep. gr.87 - Air conditioning system  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
Golf GTE, Passat GTE  
Vehicle  
Adapters required for refriger‐ Adapters required for re‐  
ant pipes to air conditioner frigerant pipes to receiver  
compressor  
Miscellaneous  
Golf GTE, Passat  
GTE  
♦ Low pressure side adapter There are two versions of  
- VAS 6338/12- connected the receiver. See vehicle  
Install a–dapter - VAS  
6338/38- in place of ex‐  
pansion valve (or a dril‐  
led out expansion valve  
⇒ page 96 )  
to air conditioner service  
specific repair manual.  
station and adapter - VAS ♦ Receiver with perma‐  
6338/48- .  
nently fitted desiccator.  
Repl–ace shut-off  
♦ High pressure side adapter  
- VAS 6338/3-  
Can–be flushed.  
After flu–shing, install a  
new receiver.  
valves -N541- and -  
N542- with two shut-off  
taps - VAS 6338/42- .  
See notes  
♦ Flushing electric air condi‐  
tioner compressor adapter  
- VAS 6338/40- and adapt‐  
er - VAS 6338/41- , see  
notes: ⇒ page 155  
♦
Receiver with desic‐  
cant bag or cartridge  
⇒ page 112  
Remove–restrictor in re‐  
frigerant line to heat ex‐  
changer for high-volt‐  
age battery, and drill it  
out (see notes below)  
⇒ page 112 .  
Remo–ve desiccant  
bag/cartridge and seal  
receiver.  
After flu–shing, install a  
new desiccant bag/car‐  
tridge.  
lk  
♦ With an electric air con‐  
ditioning compressor,  
the refrigerant oil is to  
be removed in the di‐  
rection of flow by flush‐  
ing (flushing in the op‐  
posite direction of flow  
is not possible due to  
the integrated valves).  
♦
The air conditioner  
compressor must be  
positioned for flushing  
so that the connection  
for the refrigerant line  
on the high pressure  
side is at the lowest  
point possible.  
1. Refrigerant circuit  
111  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
Note  
♦ In the Golf GTE and Passat GTE, the refrigerant circuit is  
flushed in 2 cycles. For the first cycle, the adapter for shut-off  
lk  
valve -N541- is open, and the adapter for shut-off valve -N542-  
is closed. This will cause the refrigerant circuit with the evap‐  
orator in the heater and air conditioning unit to be flushed. For  
the second cycle, the adapter for shut-off valve -N541- is  
closed, and the adapter for shut-off valve -N542- is open. The  
refrigerant circuit with the evaporator in the heat exchanger for  
high-voltage battery is flushed in this way ⇒ Heating, air con‐  
ditioning system; Rep. gr. 87 ; Refrigerant circuit (vehicle-  
specific workshop manual).  
♦ The illustration shows a refrigerant line -A- with a permanently  
installed restrictor -B- (without strainer). This refrigerant line  
must be drilled open with a suitable 5 mm drill bit (remove the  
restrictor if it is removable), and it must be cleaned before it is  
installed in the flushing circuit. After flushing, the drilled out  
refrigerant line must be renewed ⇒ Electronic parts cata‐  
logue .  
♦ The diameter of the shown restrictor hole -B- is  
approx. 0.7 mm. Depending on the refrigerant line version, this  
restrictor is permanently installed or it can be removed. For the  
removable version a strainer may be fitted to prevent the re‐  
strictor hole from being blocked by suspended particles.  
♦ The type of receiver may differ depending on the manufacturer  
of the condenser. In this example, the receiver is integrated in  
the condenser. Installed in the integrated receiver is a desic‐  
cant cartridge that is currently not always available as a re‐  
placement part. Therefore, it may be necessary to renew the  
complete condenser after eliminating any faults on vehicles  
fitted with this condenser ⇒ Electronic parts catalogue and ⇒  
Heating, air conditioning system; Rep. gr. 87 ; Refrigerant cir‐  
cuit (vehicle-specific workshop manual).  
♦ On vehicles having condensers with an integrated receiver/  
desiccant cartridge which cannot be renewed separately or  
which is not available as a replacement part, the condenser  
must be renewed after flushing (with installed desiccant car‐  
tridge) ⇒ Heating, air conditioning system; Rep. gr. 87 ;  
Refrigerant circuit (vehicle-specific workshop manual) and ⇒  
Electronic parts catalogue .  
112  
Rep. gr.87 - Air conditioning system  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
Golf Cabriolet 2012 ▶, Scirocco 2015 ▶  
Vehicle  
Adapters required for refriger‐ Adapters required for re‐  
ant pipes to air conditioner frigerant pipes to receiver  
compressor  
Miscellaneous  
Golf Cabriolet 2012 ▶, ♦ Low pressure side adapter There are two versions of  
Scirocco 2015 ▶ - VAS 6338/12- connected the receiver. See vehicle  
to air conditioner service specific repair manual.  
Install a–dapter - VAS  
6338/18- in place of ex‐  
pansion valve (or a dril‐  
led out expansion valve  
⇒ page 96 )  
station and adapter - VAS ♦ Receiver with perma‐  
6338/48- .  
nently fitted desiccator.  
♦ High pressure side adapter  
- VAS 6338/3-  
Can–be flushed.  
After flu–shing, install a  
new receiver.  
After flu–shing, install a  
new expansion valve.  
♦
Receiver with desic‐  
cant bag or cartridge  
Remo–ve desiccant  
bag/cartridge and seal  
receiver.  
After flu–shing, install a  
new desiccant bag/car‐  
tridge.  
lk  
Note  
On vehicles having condensers with an integrated receiver/des‐  
iccant cartridge which cannot be renewed separately or which is  
not available as a separate replacement part, the condenser must  
be renewed after flushing (together with integrated desiccant car‐  
tridge) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant  
circuit; System overview - refrigerant circuit and ⇒ Electronic  
parts catalogue .  
Passat 2015 ▶, Passat Estate 2015 ▶, Passat 2018 ▶, Passat  
Estate 2018 ▶  
Note  
In the Passat 2015 and Passat Estate 2015 with bi-turbo engine,  
the refrigerant circuit is not flushed. In these vehicles, it would  
require too much effort to remove the expansion valve. If the air  
conditioner compressor is defective, check whether swarf has  
entered the condenser or whether there is swarf in the condenser  
outlet. If there is only swarf on the inlet side but not on the outlet  
side, renew only the condenser and the air conditioner compres‐  
sor.  
Vehicle  
Adapters required for refriger‐ Adapters required for re‐  
Miscellaneous  
ant pipes to air conditioner frigerant pipes to receiver  
compressor  
Passat 2015 ▶, Pas‐ ♦ Low pressure side adapter  
Remo–ve desiccant  
bag/cartridge and seal  
receiver.  
Install a–dapter - VAS  
6338/18- or adapter -  
VAS 6338/38- (or a dril‐  
led out expansion valve  
⇒ page 96 ) in place of  
expansion valve  
sat Estate 2015 ▶,  
Passat 2018 ▶, Pas‐  
sat Estate 2018 ▶  
- VAS 6338/12- connected  
to air conditioner service  
station and adapter - VAS  
6338/48- .  
After flu–shing, install a  
new desiccant bag/car‐  
tridge.  
♦ High pressure side adapter  
- VAS 6338/3-  
After flu–shing, install a  
new expansion valve.  
1. Refrigerant circuit  
113  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
Note  
On vehicles having condensers with an integrated receiver/des‐  
iccant cartridge which cannot be renewed separately or which is  
not available as a separate replacement part, the condenser must  
be renewed after flushing (together with integrated desiccant car‐  
tridge) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant  
circuit; System overview - refrigerant circuit and ⇒ Electronic  
parts catalogue .  
Polo 2014 ►  
Vehicle  
Adapters required for refrigerant pipes to Adapters required for re‐  
Miscellaneous  
air conditioner compressor  
frigerant pipes to receiver  
Polo 2014 ▶ ♦ Low pressure side adapter - VAS  
6338/12- connected to air conditioner  
service station and adapter - VAS  
6338/48- .  
Remove–desiccant car‐  
tridge and seal receiv‐  
er.  
Install a–dapter - VAS  
6338/39- in place of ex‐  
pansion valve (or a dril‐  
led out expansion valve  
⇒ page 96 )  
After flu–shing, install a  
new dryer cartridge.  
♦
High pressure side adapter - VAS  
6338/3-  
After flu–shing, install a  
new expansion valve.  
♦ For air conditioner compressors 6Q0  
820 808 F and 6Q0 820 808 G on high  
pressure side adapter - VAS 6338/2-  
lk  
Polo 2018 ▶  
Vehicle  
Adapters required for refrigerant pipes to Adapters required for re‐  
Miscellaneous  
air conditioner compressor  
frigerant pipes to receiver  
Polo 2018 ▶ ♦ Low-pressure side adapter - VAS  
6338/12-  
Remo–ve desiccant  
bag/cartridge and seal  
receiver.  
Install a–dapter - VAS  
6338/38- in place of ex‐  
pansion valve (or a dril‐  
led out expansion valve  
⇒ page 96 )  
♦
High pressure side adapter - VAS  
6338/3-  
After flu–shing, install a  
new desiccant bag/car‐  
tridge.  
♦ Adapter - VAS 6338/48- for air condi‐  
tioner service station  
After flu–shing, install a  
new expansion valve.  
Note  
On vehicles having condensers with an integrated receiver/des‐  
iccant cartridge which cannot be renewed separately or which is  
not available as a separate replacement part, the condenser must  
be renewed after flushing (together with integrated desiccant car‐  
tridge) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant  
circuit; System overview - refrigerant circuit and ⇒ Electronic  
parts catalogue .  
114  
Rep. gr.87 - Air conditioning system  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
Sharan 2016 ▶  
Vehicle  
Adapters required for refrigerant pipes Adapters required for re‐  
Miscellaneous  
to air conditioner compressor  
frigerant pipes to receiver  
Sharan 2016 ▶ ♦ Low pressure side adapter - VAS  
6338/12- connected to air condi‐  
tioner service station and adapter -  
VAS 6338/48- .  
Remove–desiccant car‐  
tridge and seal receiv‐  
er.  
Install a–dapter - VAS  
6338/18- in place of  
front expansion valve  
(or a drilled-out expan‐  
sion valve ⇒ page 96 )  
After flu–shing, install a  
new dryer cartridge.  
♦ Low-pressure line for  
second evaporator  
adapter - VAS 6338/3-  
♦ High pressure side adapter - VAS  
6338/3-  
Install a–dapter - VAS  
6338/33- in place of  
rear expansion valve  
(or a drilled-out expan‐  
sion valve ⇒ page 96 )  
♦ High-pressure line for  
second evaporator  
adapter - VAS 6338/4-  
After flu–shing, install a  
new expansion valve.  
♦ The refrigerant lines to  
the second evaporator  
must be loosened suf‐  
ficiently so that the  
adapter can be fitted  
without deforming the  
refrigerant lines.  
♦ Sealing adapter - VAS  
6338/5- for front refrig‐  
erant circuit.  
♦ Sealing adapter - VAS  
6338/11- for front re‐  
frigerant circuit.  
lk  
Note  
On vehicles having condensers with an integrated receiver/des‐  
iccant cartridge which cannot be renewed separately or which is  
not available as a separate replacement part, the condenser must  
be renewed after flushing (together with integrated desiccant car‐  
tridge) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant  
circuit; System overview - refrigerant circuit and ⇒ Electronic  
parts catalogue .  
1. Refrigerant circuit  
115  
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lk  
Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
Tiguan 2016 ▶, Tiguan MEX 2017 ▶  
Vehicle  
Adapters required for refriger‐ Adapters required for re‐  
ant pipes to air conditioner frigerant pipes to receiver  
compressor  
Miscellaneous  
Tiguan 2016 ▶, Ti‐  
guan MEX 2017 ▶  
♦ Low pressure side adapter  
- VAS 6338/12- connected  
to air conditioner service  
station and adapter - VAS  
6338/48- .  
Remo–ve desiccant  
bag/cartridge and seal  
receiver.  
Install a–dapter - VAS  
6338/38- in place of ex‐  
pansion valve (or a dril‐  
led out expansion valve  
⇒ page 96 )  
After flu–shing, install a  
new desiccant bag/car‐  
tridge.  
♦ High pressure side adapter  
- VAS 6338/3-  
After flu–shing, install a  
new expansion valve.  
If a cond–enser/receiver  
with permanently in‐  
stalled desiccant bag /  
cartridge is installed,  
leave the condenser/  
receiver in situ and  
flush the refrigerant cir‐  
cuit.  
After flu–shing, install a  
new receiver.  
Note  
On vehicles having condensers with an integrated receiver/des‐  
iccant cartridge which cannot be renewed separately or which is  
not available as a separate replacement part, the condenser must  
be renewed after flushing (together with integrated desiccant car‐  
tridge) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant  
circuit; System overview - refrigerant circuit and ⇒ Electronic  
parts catalogue .  
Touareg 2015 ▶  
Vehicle  
Adapters required for refrigerant  
Adapters required for re‐  
Miscellaneous  
pipes to air conditioner compressor frigerant pipes to receiver  
Touareg 2015 ▶ ♦ Low pressure side adapter - VAS  
6338/12- connected to air condi‐  
tioner service station and adapter  
- VAS 6338/48- .  
Remove–desiccant car‐  
tridge and seal receiv‐  
er.  
Install a–dapter - VAS  
6338/17- or adapter -  
VAS 6338/33- in place  
of front and rear expan‐  
sion valves (or a drilled  
out expansion valve  
⇒ page 96 )  
After flu–shing, install a  
new dryer cartridge.  
♦ Low-pressure line for  
second evaporator  
adapter - VAS 6338/3-  
♦ High-pressure side adapter - VAS  
6338/2- or adapter - VAS 6338/3-  
♦
Electrical air conditioner com‐  
pressor, adapter - VAS 6338/40-  
and adapter - VAS 6338/41-  
After flu–shing, install a  
new expansion valve.  
♦ High-pressure line for  
second evaporator  
adapter - VAS 6338/4-  
♦ Sealing adapter - VAS  
6338/5- for front refrig‐  
erant circuit.  
♦ Sealing adapter - VAS  
6338/11- for front re‐  
frigerant circuit.  
116  
Rep. gr.87 - Air conditioning system  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
Note  
On vehicles having condensers with an integrated receiver/des‐  
iccant cartridge which cannot be renewed separately or which is  
not available as a separate replacement part, the condenser must  
be renewed after flushing (together with integrated desiccant car‐  
tridge) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant  
circuit; System overview - refrigerant circuit and ⇒ Electronic  
parts catalogue .  
lk  
up! 2017 ▶, e-up! 2017 ▶  
Vehicle  
Adapters required for refriger‐ Adapters required for re‐  
ant pipes to air conditioner frigerant pipes to receiver  
compressor  
Miscellaneous  
up! 2017 ▶, e-up! 2017 ♦ Low pressure side adapter  
Receive–r can be flush‐  
ed.  
Install a–dapter - VAS  
6338/36- or adapter -  
VAS 6338/34- (or a dril‐  
led out expansion valve  
⇒ page 96 ) in place of  
expansion valve  
▶
- VAS 6338/12- connected  
to air conditioner service  
station and adapter - VAS  
6338/48- .  
After flu–shing, install a  
new receiver.  
♦ High pressure side adapter  
- VAS 6338/3-  
After flu–shing, install a  
new expansion valve.  
♦ Flushing electric air condi‐  
tioner compressor adapter -  
VAS 6338/40- and adapter  
- VAS 6338/41- , see notes:  
⇒ page 155  
Note  
On vehicles having condensers with an integrated receiver/des‐  
iccant cartridge which cannot be renewed separately or which is  
not available as a separate replacement part, the condenser must  
be renewed after flushing (together with integrated desiccant car‐  
tridge) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant  
circuit; System overview - refrigerant circuit and ⇒ Electronic  
parts catalogue .  
1. Refrigerant circuit  
117  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
Jetta 2015 ▶, The Beetle 2017 ▶, The Beetle Cabriolet 2017 ▶  
Vehicle  
Adapters required for refriger‐ Adapters required for re‐  
ant pipes to air conditioner frigerant pipes to receiver  
compressor  
Miscellaneous  
Jetta 2015 ▶, The Bee‐ ♦ Low-pressure side adapter  
Remo–ve desiccant  
bag/cartridge and seal  
receiver.  
Install a–dapter - VAS  
6338/18- (or a drilled  
out expansion valve  
⇒ page 96 ) in place of  
expansion valve.  
tle 2017 ▶, The Beetle  
Cabriolet 2017 ▶  
- VAS 6338/12-  
♦ High pressure side adapter  
- VAS 6338/3-  
After flu–shing, install a  
lk  
new desiccant bag/car‐  
♦ Adapter - VAS 6338/48- for  
air conditioner service sta‐  
tion  
tridge.  
After flu–shing, install a  
new expansion valve.  
If a cond–enser/receiver  
with permanently in‐  
stalled desiccant bag /  
cartridge is installed,  
leave the condenser/  
receiver in situ and  
flush the refrigerant cir‐  
cuit.  
After flu–shing, install a  
new receiver.  
Note  
On vehicles having condensers with an integrated receiver/des‐  
iccant cartridge which cannot be renewed separately or which is  
not available as a separate replacement part, the condenser must  
be renewed after flushing (together with integrated desiccant car‐  
tridge) ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant  
circuit; System overview - refrigerant circuit and ⇒ Electronic  
parts catalogue .  
Jetta 2018 ▶, The Beetle 2018 ▶, The Beetle Cabriolet 2018 ▶  
Vehicle  
Adapters required for refriger‐ Adapters required for re‐  
Miscellaneous  
ant pipes to air conditioner frigerant pipes to receiver  
compressor  
Jetta 2018 ▶, The Bee‐ ♦ Low-pressure side adapter  
Remo–ve desiccant  
bag/cartridge and seal  
receiver.  
Install a–dapter - VAS  
6338/18- (or a drilled  
out expansion valve  
⇒ page 96 ) in place of  
expansion valve.  
tle 2018 ▶, The Beetle  
Cabriolet 2018 ▶  
- VAS 6338/12-  
♦ High pressure side adapter  
- VAS 6338/3-  
After flu–shing, install a  
new desiccant bag/car‐  
tridge.  
♦ Adapter - VAS 6338/48- for  
air conditioner service sta‐  
tion  
After flu–shing, install a  
new expansion valve.  
If a cond–enser/receiver  
with permanently in‐  
stalled desiccant bag /  
cartridge is installed,  
leave the condenser/  
receiver in situ and  
flush the refrigerant cir‐  
cuit.  
After flu–shing, install a  
new receiver.  
118  
Rep. gr.87 - Air conditioning system  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
Commercial vehicles  
Note  
For a detailed description of assembling the flushing circuit, refer  
to the workshop manual ⇒ Air conditioning system with refrigerant  
R134a; Rep. gr. 00 ; Cleaning refrigerant circuit, commercial ve‐  
hicles .  
Caddy 2016 ▶  
Vehicle  
Adapters required for re‐ Adapters required for re‐  
Miscellaneous  
frigerant pipes to air con‐ frigerant pipes to receiver  
ditioner compressor  
Caddy 2016 ▶  
♦
Low-pressure side  
adapter - VAS  
6338/12-  
Vehicle–s with Modine  
condensers:  
Install a–dapter - VAS  
6338/18- (or a drilled  
out expansion valve  
⇒ page 96 ) in place of  
expansion valve.  
♦ Remove desiccant bag  
and seal receiver.  
♦
♦
High pressure side  
adapter - VAS 6338/3-  
Vehicle–s with Showa  
condensers:  
After flu–shing, install a  
new expansion valve.  
Adapter - VAS  
♦
Flush desiccant car‐  
tridge also.  
6338/48- for air condi‐  
tioner service station  
After flu–shing, install a  
new desiccant bag/car‐  
tridge.  
Crafter 2017 or MAN TGE ▶  
Vehicle  
Adapters required for re‐ Adapters required for re‐  
Miscellaneous  
frigerant pipes to air con‐ frigerant pipes to receiver  
lk  
ditioner compressor  
Crafter 2017 or MAN  
TGE ▶  
♦
Low-pressure side  
adapter - VAS  
6338/12-  
♦ If the vehicle has a sec‐  
ond evaporator, the  
rear refrigerant circuit  
(roof air conditioning  
system) must be rinsed  
first.  
Install a–dapter - VAS  
6338/38- (or a drilled  
out expansion valve  
⇒ page 96 ) in place of  
expansion valve.  
♦
♦
High pressure side  
adapter - VAS 6338/3-  
After flu–shing, install a  
new expansion valve.  
Adapter - VAS  
Remove–desiccant bag  
and seal receiver.  
6338/48- for air condi‐  
tioner service station  
After flu–shing, install a  
new desiccant bag.  
♦ Adapter - VAS 6338/5-  
for low pressure side of  
front refrigerant circuit.  
♦
Adapter - VAS  
6338/63- for high pres‐  
sure side of front refrig‐  
erant circuit.  
♦ Adapt low pressure line  
for second evaporator  
using adapter - VAS  
6338/3- .  
♦
Adapt high pressure  
line for second evapo‐  
rator using adapter -  
VAS 6338/60- .  
1. Refrigerant circuit  
119  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
Transporter 2016 ▶  
Vehicle  
Adapters required for re‐ Adlkapters required for re‐  
frigerant pipes to air con‐ frigerant pipes to receiver  
ditioner compressor  
Miscellaneous  
Transporter 2016 ▶  
♦
Low-pressure side  
adapter - VAS  
6338/12-  
Remove–desiccant bag  
and seal receiver.  
After flu–shing, install a  
new desiccant bag.  
Adapter - VAS  
Install a–dapter - VAS  
6338/56- (or a drilled  
out expansion valve  
⇒ page 96 ) in place of  
expansion valve.  
♦
♦
High pressure side  
♦
♦
adapter - VAS 6338/3-  
6338/63- for high pres‐  
sure side of front refrig‐  
erant circuit.  
Remove–and drill open  
expansion valve for  
rear evaporator  
Adapter - VAS  
6338/48- for air condi‐  
tioner service station  
Adapter - VAS  
6338/64- for low pres‐  
sure side of front refrig‐  
erant circuit.  
⇒ page 96 .  
After fl–ushing, install  
new expansion valves.  
♦ Adapt low pressure line  
for second evaporator  
using adapter - VAS  
6338/61- .  
♦ Seal low pressure line  
for 2nd evaporator us‐  
ing adapter - VAS  
6338/62- .  
♦
Adapt high pressure  
line for second evapo‐  
rator using adapter -  
VAS 6338/60- .  
On ve–hicles with 1  
evaporator system,  
flush once.  
On ve–hicles with 2  
evaporator systems,  
flush twice.  
1.6.9  
General information about blowing  
through with compressed air or nitrogen  
In order to remove moisture and other contaminants as well as  
old refrigerant oil from the refrigerant circuit as cleanly as possi‐  
ble, without wasting the refrigerant and in an uncomplicated and  
environmentally compatible way, the refrigerant circuit must be  
cleaned with refrigerant R1234yf (flushed with R1234yf refriger‐  
ant) ⇒ “1.6 Cleaning refrigerant circuit”, page 92 .  
Blowing through the refrigerant circuit with compressed air and  
nitrogen is a method to be applied e.g. only if individual compo‐  
nents are to be cleaned.  
120  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
Note  
♦ The refrigerant circuit should then only be blown through with  
compressed air and then with nitrogen if there are no means  
of flushing the refrigerant circuit, or the amount of work nec‐  
essary to flush individual components would be too great  
(removed refrigerant lines can also be blown through, for ex‐  
ample, to remove low level contaminants and moisture without  
taking much time).  
♦ The method of blowing through the whole refrigerant circuit  
with compressed air and nitrogen often requires a lot more  
work than cleaning (flushing) with refrigerant R1234yf. When  
flushing with refrigerant R1234yf, cleaning of the components  
is also far more efficient. It is therefore always best to flush the  
system in the event of complaints (the method of blowing  
through should only be selected for certain complaints and for  
individual components).  
lk  
♦ Under certain circumstances it may be sufficient, for example,  
to blow through selected components (e.g. individual refriger‐  
ant lines or refrigerant hoses) with compressed air (e.g. to  
force out old refrigerant oil from individual removed compo‐  
nents) or nitrogen (to dry individual components).  
♦ Certain contaminants are difficult or impossible to remove  
from the refrigerant circuit with compressed air. These con‐  
taminants can be removed, for example, by cleaning (flushing)  
with refrigerant R1234yf  
⇒ “1.6 Cleaning refrigerant circuit”, page 92 .  
♦ When blowing through (with compressed air or nitrogen), the  
maximum working pressure should not exceed 15 bar (equa‐  
tes to the pressure in a filled refrigerant circuit with an ambient  
temperature of approx. 60°C, if necessary use pressure limiter  
for compressed air as well).  
♦ If during the gas analysis it is found that R1234yf refrigerant  
has been contaminated with a different gas, it must be extrac‐  
ted from the refrigerant circuit and disposed of as a gas of  
unknown composition in accordance with the relevant legisla‐  
tion ⇒ VW / Audi-ServiceNet and ⇒ page 161 .  
♦ Contaminated refrigerant can cause decomposition products  
to form and accumulate in the refrigerant circuit. These cannot  
be extracted with the refrigerant. The contaminated refrigerant  
oil, in this case, must be removed from the refrigerant circuit  
by flushing with refrigerant  
⇒ “1.6 Cleaning refrigerant circuit”, page 92 .  
♦ If there is no suitable air conditioner service station available  
for the R1234yf refrigerant, the air conditioner service station  
designed for R134a refrigerant may also be used and the re‐  
frigerant circuit may also be flushed with R134a refrigerant.  
Using R134a refrigerant to clean the refrigerant circuit is cur‐  
rently permissible ⇒ Air conditioning system with R134a re‐  
frigerant; Rep. gr. 87 ; Refrigerant circuit; Flushing (cleaning)  
refrigerant circuit with R134a refrigerant .  
CAUTION  
Risk of injury from nitrogen escaping under high pressure.  
– Use pressure limiter for nitrogen tank.  
– Always clean components against the direction of refrigerant  
flow (flush with R1234yf refrigerant) or blow through.  
1. Refrigerant circuit  
121  
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– Extract the mixture of refrigerant, refrigerant oil, compressed  
air or nitrogen escaping out of the components with an extrac‐  
tion system.  
Note  
Compressed air and nitrogen cannot be blown through the re‐  
strictor, expansion valve, air conditioner compressor, receiver or  
reservoir.  
– In cases where condensers have a drying agent cartridge in  
the integrated receiver, this drying agent cartridge must be re‐  
moved.  
Note  
♦ With condensers in which the receiver / desiccant cartridge are  
integrated and cannot be renewed individually, the condenser  
lk  
is to be renewed after cleaning (flushing).  
♦ Depending on the version, receivers - in which the desiccant  
cartridge is to be renewed individually - may feature an addi‐  
tional filter element, which will need to be renewed with the  
desiccant cartridge if necessary.  
– First blow out old refrigerant oil and contaminants with com‐  
pressed air, then blow out components with nitrogen (clean,  
blow out or dehumidify old refrigerant oil).  
– Adapter for connecting pressure hose to refrigerant circuit  
Adapter case for VW/Audi passenger vehicles ⇒ Electronic  
parts catalogue .  
To prevent oil and moisture from the compressed air system  
making its way into the refrigerant circuit, the following points must  
be observed.  
♦ The compressed air must be fed through a compressed air  
cleaning unit to clean and dry it. Therefore, use a filter and  
dryer for compressed air (included in the supply of tools for  
paint systems) ⇒ Electronic parts catalogue .  
♦ On refrigerant lines with threads or union nuts on the connec‐  
tion, use adapter from refrigerant circuit adapter set - V.A.G  
1785- ( adapter - V.A.G 1785/1- to adapter - V.A.G 1785/8- )  
to connect the 5/8" - 18 UNF charges hose (one part of this  
adapter is also included in the adapter case for VW/Audi pas‐  
senger vehicles ).  
♦ On refrigerant lines without thread or union nut on the con‐  
nection (for connection of adapters), use adapter from adapter  
case VW/Audi passenger vehicle set or proprietary air blow  
gun with rubber nozzle.  
Note  
Always extract any escaping air and/or nitrogen from the compo‐  
nents using appropriate local exhaust ventilation LEV (e.g. work‐  
shop extraction system).  
The refrigerant circuit (or individual components) must be blown  
through if there are no means of flushing or flushing does not ap‐  
pear to be the appropriate solution.  
– if there is dirt or contamination in individual components of the  
refrigerant circuit.  
122  
Rep. gr.87 - Air conditioning system  
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Related Topics

Air conditioning system

1 Refrigerant circuit
1.1 System overview - refrigerant circuit
1.1.1 System overview - refrigerant circuit with expansion valve and receiver
1.1.2 System overview - refrigerant circuit with restrictor and reservoir
1.1.3 System overview - refrigerant circuit with electrically driven air conditioner compressor
1.2 General description - components of refrigerant circuit
1.2.1 Layout and function of refrigerant circuit
1.2.2 Mechanical air conditioner compressor
1.2.3 Electrical air conditioner compressor for hybrid vehicles
1.2.4 Condenser
1.2.5 Evaporator
1.2.6 Reservoir
1.2.7 Heat exchanger for heat pump mode
1.2.8 Liquid receiver
1.2.9 Restrictor
1.2.10 Receiver
1.2.11 Expansion valve (with and without shut-off valve)
1.2.12 Refrigerant shut-off valves
1.2.13 Refrigerant line with internal heat exchanger
1.2.14 Quick release couplings of refrigerant lines
1.2.15 Seals
1.2.16 Pipes and hoses in refrigerant circuit
1.2.17 High-pressure safety valve
1.2.18 Non-return valves
1.2.19 Quick-release coupling connections in refrigerant circuit
1.2.20 Connections with valve for switches in refrigerant circuit
1.2.21 Pressure senders and switches in refrigerant circuit
1.2.22 Refrigerant pressure and temperature sender
1.2.23 Air conditioner compressor regulating valve N280
1.2.24 Refrigerant temperature sender
1.3 Possible complaints
1.3.1 Prerequisites for investigating a complaint
1.3.2 Possible complaints
1.3.3 Odours from heater and air conditioner unit
1.4 Investigating leaks
1.4.1 General information about investigating leaks in the refrigerant circuit
1.4.2 Searching for leaks in refrigerant circuits using an electronic leak detector
1.4.3 Searching for leaks with UV leak detection system
1.4.4 Detecting leaks in a vacuum test using air conditioner service station, or in a pressure test
1.4.5 Detecting leaks in a pressure test (with nitrogen or compressed air)
1.5 Renewing components
1.5.1 General information about renewing components
1.5.2 Renewing leaking or damaged components of empty refrigerant circuit
1.5.3 Renewing leaking or damaged components of charged refrigerant circuit
1.5.4 Renewing air conditioner compressor with no need to clean refrigerant circuit
1.5.5 Renewing air conditioner compressor due to leaks or internal damage
1.5.6 Renewing desiccant cartridge / receiver after cleaning refrigerant circuit
1.5.7 Renewing receiver with no need to clean refrigerant circuit
1.5.8 Renewing desiccant cartridge / desiccant bag with no need to clean refrigerant circuit
1.6.1 General information about cleaning refrigerant circuit
1.6.2 Preparations for cleaning refrigerant circuit (flushing with R1234yf refrigerant)
1.6.3 Refrigerant circuit cleaning procedure
1.6.4 Principle circuit diagrams for cleaning (flushing circuits) - refrigerant circuit with expansion valve and receiver
1.6.5 Principle circuit diagrams for cleaning (flushing circuits) - refrigerant circuit with restrictor and receiver
1.6.6 Principle circuit diagrams for cleaning (flushing circuits) - vehicles with high-voltage system (without auxiliary)
1.6.7 Principle circuit diagrams for cleaning (flushing circuits) - vehicles with high-voltage system (with auxiliary)
1.6.8 Adapters for setting up flushing circuits
1.6.9 General information about blowing through with compressed air or nitrogen
1.6.10 Blowing through refrigerant circuit with compressed air or nitrogen
1.7 Checking pressures with pressure gauge
1.7.1 Display on pressure gauges
1.7.2 Pressure gauges enable the following test and measurement work
2 Working with air conditioner service station
2.1 Working with air conditioner service station
2.2 Connecting air conditioner service station to refrigerant circuit
2.3 Performing gas analysis of refrigerant
2.4 Emptying refrigerant circuit
2.5 Evacuating refrigerant circuit
2.6 Charging refrigerant circuit
2.7 Bringing air conditioning system into service after charging
2.8 Switching off air conditioner service station and separating from refrigerant circuit
2.9 Charging refrigerant in reservoir
2.10 Emptying air conditioner service station
2.11 Cleaning electrical air conditioning compressor
2.12 Cleaning refrigerant circuit
2.13 Filling contaminated refrigerant in a recycling cylinder for analysis, processing or disposal
2.13.1 Filling contaminated refrigerant in a recycling cylinder using technical equipment
2.13.2 Filling undercooled contaminated refrigerant in a recycling cylinder
2.14 Checking pressures
2.14.1 General information on checking pressures in the refrigerant circuit
2.14.2 Pressures and temperatures in refrigerant circuit
2.14.3 Checking pressures in the refrigerant circuit with the ignition switched off
2.14.4 Checking pressures with air conditioning system switched on - vehicles with mechanical air conditioning compressor
2.14.5 Checking pressures with air conditioning system switched on - vehicles with electrical air conditioning compressor
3 Testing equipment and tools
3.1 Tools and materials available from distribution centre or importer
3.2 Tools and materials available commercially
3.3 Tools that can be locally manufactured

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