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Air conditioning system -> 1 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  
87 – Air conditioning system  
1
Refrigerant circuit  
⇒ “1.1 System overview - refrigerant circuit”, page 30  
⇒ “1.2 General description - components of refrigerant circuit”,  
page 36  
⇒ “1.3 Possible complaints”, page 64  
⇒ “1.4 Investigating leaks”, page 68  
⇒ “1.5 Renewing components”, page 79  
⇒ “1.6 Cleaning refrigerant circuit”, page 92  
⇒ “1.7 Checking pressures with pressure gauge”, page 126  
1.1  
System overview - refrigerant circuit  
⇒ “1.1.1 System overview - refrigerant circuit with expansion valve  
and receiver”, page 30  
⇒ “1.1.2 System overview - refrigerant circuit with restrictor and  
reservoir”, page 32  
⇒ “1.1.3 System overview - refrigerant circuit with electrically driv‐  
en air conditioner compressor (with and without battery cooling  
module)”, page 33  
1.1.1  
System overview - refrigerant circuit  
with expansion valve and receiver  
Note  
The arrows indicate the direction of coolant flow.  
The following diagram shows an example of a refrigerant cir‐  
cuit with 2 evaporators and one internal heat exchanger.  
The layout of the refrigerant circuit is specific to the vehicle ⇒  
Heating, air conditioning system; Rep. gr. 87 ; Refrigerant cir‐  
cuit (vehicle-specific workshop manual).  
HD = High-pressure side  
ND = Low-pressure side  
30  
Rep. gr.87 - Air conditioning system  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
1 - Air conditioner compressor  
regulating valve - N280-  
2 - Air conditioner compressor  
3 - Pulley  
❑ Depending on the ver‐  
sion, an air conditioning  
system magnetic clutch  
- N25- is installed in the  
belt pulley ⇒ Heating,  
air conditioning system;  
Rep. gr. 87 ; Refrigerant  
circuit (vehicle-specific  
workshop manual).  
❑ Depending on the ver‐  
sion there may be a  
drive unit instead of the  
belt pulley ⇒ Heating,  
air conditioning system;  
Rep. gr. 87 ; Refrigerant  
circuit (vehicle-specific  
workshop manual).  
4 - High-pressure safety valve  
5 - Refrigerant pressure send‐  
er  
❑ Vehicle-specific ver‐  
sions ⇒ Heating, air  
conditioning system;  
Rep. gr. 87 ; Refrigerant  
circuit .  
6 - Condenser (with receiver)  
7 - Receiver  
❑ Installed on, at or in the  
condenser ⇒ Heating,  
air conditioning system;  
Rep. gr. 87 ; Refrigerant  
circuit (vehicle-specific workshop manual).  
❑ With desiccant cartridge  
8 - Service connection, high-pressure side  
❑ With sealing cap  
9 - Refrigerant line with internal heat exchanger  
10 - Front expansion valve  
11 - Front evaporator  
❑ Evaporator in front heater and air conditioning unit (installed under dash panel)  
12 - Service connection, low-pressure side  
❑ With sealing cap  
13 - Rear expansion valve  
❑ Only on vehicles with rear air conditioning unit (extra equipment)  
14 - Rear evaporator  
❑ Only on vehicles with rear air conditioning unit (extra equipment)  
1. Refrigerant circuit  
31  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
1.1.2  
System overview - refrigerant circuit  
with restrictor and reservoir  
Note  
The arrows indicate the direction of coolant flow.  
The following diagram shows an example of a refrigerant cir‐  
cuit with one evaporator.  
This refrigerant circuit layout is currently not planned for VW/  
Audi vehicles.  
The layout of the refrigerant circuit is specific to the vehicle ⇒  
Heating, air conditioning system; Rep. gr. 87 ; Refrigerant cir‐  
cuit (vehicle-specific workshop manual).  
HD = High-pressure side  
ND = Low-pressure side  
1 - Air conditioner compressor  
regulating valve - N280-  
2 - Air conditioner compressor  
3 - Pulley  
❑ Depending on the ver‐  
sion, an air conditioning  
system magnetic clutch  
- N25- is installed in the  
belt pulley ⇒ Heating,  
air conditioning system;  
Rep. gr. 87 ; Refrigerant  
circuit (vehicle-specific  
workshop manual).  
❑ Depending on the ver‐  
sion there may be a  
drive unit instead of the  
belt pulley ⇒ Heating,  
air conditioning system;  
Rep. gr. 87 ; Refrigerant  
circuit (vehicle-specific  
workshop manual).  
4 - High-pressure safety valve  
5 - Condenser  
6 - Refrigerant pressure send‐  
er  
❑ Vehicle-specific ver‐  
sions ⇒ Heating, air  
conditioning system;  
Rep. gr. 87 ; Refrigerant  
circuit (vehicle-specific  
workshop manual).  
7 - Service connection, high-  
pressure side  
❑ With sealing cap  
8 - Restrictor  
9 - Evaporator  
❑ Evaporator in front heater and air conditioning unit (installed under dash panel)  
32  
Rep. gr.87 - Air conditioning system  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
10 - Service connection, low-pressure side  
❑ With sealing cap  
11 - Reservoir  
❑ With desiccant cartridge  
1.1.3  
System overview - refrigerant circuit  
with electrically driven air conditioner  
compressor (with and without battery  
cooling module)  
Note  
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The arrows indicate the direction of coolant flow.  
The following diagram shows an example of a refrigerant cir‐  
cuit with expansion valve and second evaporator for battery  
cooling and one internal heat exchanger.  
The layout of the refrigerant circuit is specific to the vehicle ⇒  
Heating, air conditioning system; Rep. gr. 87 ; Refrigerant cir‐  
cuit (vehicle-specific workshop manual).  
HD = High-pressure side  
ND = Low-pressure side  
1. Refrigerant circuit  
33  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
1 - Electrical air conditioner  
compressor  
❑ With control unit for air  
conditioner compressor  
- J842- and electrical air  
conditioner compressor  
- V470- ⇒ Heating, air  
conditioning system;  
Rep. gr. 87 ; Refrigerant  
circuit (vehicle-specific  
workshop manual).  
2 - High-pressure safety valve  
3 - Condenser  
❑ With receiver and desic‐  
cant cartridge.  
4 - Receiver  
❑ Part of condenser in this  
case.  
5 - Refrigerant pressure send‐  
er  
❑ Vehicle-specific ver‐  
sions ⇒ Heating, air  
conditioning system;  
Rep. gr. 87 ; Refrigerant  
circuit (vehicle-specific  
workshop manual).  
6 - Service connection, high-  
pressure side  
❑ With sealing cap.  
7 - Refrigerant line with internal  
heat exchanger  
8 - Refrigerant shut-off valve  
❑ Different designations  
⇒ Heating, air condi‐  
tioning system; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).  
❑ Only on vehicles with battery cooling module for hybrid battery unit - AX1-  
Note  
The refrigerant shut-off valve is ac‐  
tuated e.g. if battery cooling is nec‐  
essary and no cooling of the pas‐  
senger compartment is required  
(open when not actuated).  
9 - Expansion valve  
❑ On evaporator in heater and air conditioning unit  
10 - Front evaporator  
❑ Evaporator in heater and air conditioning unit  
11 - -Expansion valve with shut-off valve-  
❑ Different designations ⇒ Heating, air conditioning system; Rep. gr. 87 ; Refrigerant circuit (vehicle-  
specific workshop manual).  
❑ On evaporator in battery cooling module  
❑ Only on vehicles with battery cooling module for hybrid battery unit - AX1-  
34  
Rep. gr.87 - Air conditioning system  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
Note  
The -expansion valve with shut-off  
valve- is actuated if battery cooling  
is necessary (closed when not actu‐  
ated).  
12 - Evaporator  
❑ Evaporator in battery cooling module  
❑ Only on vehicles with battery cooling module for hybrid battery unit - AX1-  
13 - Service connection, low-pressure side  
❑ With sealing cap  
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1. Refrigerant circuit  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
1.2  
General description - components of re‐  
frigerant circuit  
⇒ “1.2.1 Layout and function of refrigerant circuit”, page 36  
⇒ “1.2.2 Mechanical air conditioner compressor”, page 38  
⇒ “1.2.3 Electrical air conditioner compressor for hybrid vehicles”,  
page 40  
⇒ “1.2.4 Condenser”, page 43  
⇒ “1.2.5 Evaporator”, page 43  
⇒ “1.2.6 Reservoir”, page 44  
⇒ “1.2.7 Heat exchanger for heat pump mode”, page 45  
⇒ “1.2.8 Liquid receiver”, page 45  
⇒ “1.2.9 Restrictor”, page 46  
⇒ “1.2.10 Receiver”, page 47  
⇒ “1.2.11 Expansion valve (with and without shut-off valve)”, page  
48  
⇒ “1.2.12 Refrigerant shut-off valves”, page 50  
⇒ “1.2.13 Refrigerant line with internal heat exchanger”,  
page 51  
⇒ “1.2.14 Quick release couplings of refrigerant lines”,  
page 51  
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⇒ “1.2.15 Seals”, page 52  
⇒ “1.2.16 Pipes and hoses in refrigerant circuit”, page 52  
⇒ “1.2.17 High-pressure safety valve”, page 53  
⇒ “1.2.18 Non-return valves”, page 54  
⇒ “1.2.19 Quick-release coupling connections in refrigerant cir‐  
cuit”, page 55  
⇒ “1.2.20 Connections with valve for switches in refrigerant circuit  
”, page 59  
⇒ “1.2.21 Pressure senders and switches in refrigerant circuit”,  
page 59  
⇒ “1.2.22 Refrigerant pressure and temperature sender”,  
page 60  
⇒ “1.2.23 Air conditioner compressor regulating valve N280 ”,  
page 63  
⇒ “1.2.24 Refrigerant temperature sender”, page 63  
1.2.1  
Layout and function of refrigerant circuit  
♦ Located on the high-pressure side are the condenser, receiver  
and restrictor or expansion valve to separate the high-pres‐  
sure side (HD) and low-pressure side (ND).  
♦ High pressure is created by the restrictor or expansion valve  
forming a constriction and causing the refrigerant to build up,  
thus leading to increased pressure and temperature.  
♦ Excessive pressure results if the circuit is filled with too much  
refrigerant or refrigerant oil, or the condenser is dirty, the ra‐  
diator fan is defective, there is a blockage in the system or  
there is moisture in the refrigerant circuit (causing the restrictor  
or expansion valve to ice up).  
36  
Rep. gr.87 - Air conditioning system  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
♦ Located on the low-pressure side are the evaporator, the tem‐  
perature sensor for the evaporator and the air conditioner  
compressor that acts as the separation between the high-  
pressure (HD) and low-pressure (ND) gas sides.  
♦ A loss of pressure in the system can be due to loss of refrig‐  
erant, restrictor or expansion valve defective or blocked, de‐  
fective air conditioner compressor or an iced-up evaporator.  
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1. Refrigerant circuit  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
1.2.2  
Mechanical air conditioner compressor  
The air conditioner compressor is driven by a poly V-belt -B- or a  
shaft by the engine.  
Air conditioner compressor with air conditioning system magnetic  
clutch - N25- :  
An electromagnetic clutch -A- attached to the air conditioner com‐  
pressor provides power transfer between pulley -B- and com‐  
pressor crankshaft when the air conditioning is switched on.  
An overload protection device attached to the clutch plate or fitted  
in the solenoid of the air conditioner compressor triggers if there  
is resistance in the air conditioner compressor (sluggish move‐  
ment), protecting the belt drive or the drive unit against overload.  
Note  
To ensure that the air conditioner compressor is not damaged  
if the refrigerant circuit is empty, the air conditioner compres‐  
sor regulating valve - N280- and, under certain circumstances,  
the air conditioning system magnetic clutch - N25- are no lon‐  
ger actuated (the air conditioner compressor only runs at idle  
with the engine if -N25- is actuated).  
An air conditioner compressor with -N25- (without -N280- ) is  
not actuated if the refrigerant circuit is empty and is therefore  
not driven.  
Air conditioner compressor without air conditioning system mag‐  
netic clutch - N25- :  
♦ An overload protection device attached to the pulley -B- or fit‐  
ted in the drive unit of the air conditioner compressor triggers  
if there is resistance in the air conditioner compressor (slug‐  
gish movement), protecting the belt drive or the drive unit  
against overload.  
♦ An air conditioner compressor with air conditioner compressor  
regulating valve - N280- (without -N25- ) is switched over to  
internal lubrication via a valve if the refrigerant circuit is empty.  
Note  
On air conditioner compressors without air conditioning sys‐  
tem magnetic clutch - N25- , the engine may only be started  
following complete assembly of the refrigerant circuit.  
To ensure that the air conditioner compressor suffers no dam‐  
age if the refrigerant circuit is empty, the air conditioner com‐  
pressor regulating valve - N280- is no longer activated (the air  
conditioner compressor idles with the engine).  
All air conditioner compressors  
The air conditioner compressor draws refrigerant gas from the  
evaporator, compresses it and sends it to the condenser.  
38  
Rep. gr.87 - Air conditioning system  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
Note  
The air conditioner compressor contains refrigerant oil, which  
can be mixed with R1234yf refrigerant at any temperature.  
The identification plate states the refrigerant for which the air  
conditioner compressor is suitable. A valve regulates the pres‐  
sure on the low-pressure side within the specified range (con‐  
trol characteristic) ⇒ Heating, air conditioning system; Rep.  
gr. 87 ; Refrigerant circuit .  
lk  
Depending on the version of air conditioner compressor, dif‐  
ferent refrigerant oils are filled in the air conditioner compres‐  
sor. Refrigerant oils that were developed for R134a refrigerant  
oil only, must not be used for R1234yf refrigerant ⇒ Heating,  
air conditioning system; Rep. gr. 00 ; Technical data; Refrig‐  
erant oil .  
Air conditioner compressors with or without air conditioning  
system magnetic clutch - N25- are currently actuated via an  
air conditioner compressor regulating valve - N280- -C- exter‐  
nally ⇒ Heating, air conditioning system; Rep. gr. 87 ; Re‐  
frigerant circuit .  
The identification plate states the refrigerant for which the air  
conditioner compressor is suitable. An air conditioner com‐  
pressor regulating valve - N280- regulates the pressure on the  
low-pressure side within the specified range (control charac‐  
teristic) ⇒ Heating, air conditioning system; Rep. gr. 87 ;  
Refrigerant circuit .  
The air conditioner compressor regulating valve - N280- is ac‐  
tuated externally ⇒ Vehicle diagnostic tester in “Guided Fault  
Finding” in air conditioning system.  
The engine must not be started in a vehicle with air conditioner  
compressor but no air conditioner compressor magnetic clutch  
- N25- if there is negative pressure in the refrigerant circuit  
(e.g. during evacuation) ⇒ page 129 .  
The engine may only be started in a vehicle with air conditioner  
compressor but no air conditioner compressor magnetic clutch  
- N25- when the refrigerant circuit has been completely as‐  
sembled.  
To ensure that the air conditioner compressor suffers no dam‐  
age if the refrigerant circuit is empty, the air conditioner com‐  
pressor regulating valve - N280- is no longer activated (the air  
conditioner compressor idles with the engine) if the pressure  
in the refrigerant circuit is too low (lower than approx. 2 bar).  
An air conditioner compressor with air conditioner compressor  
regulating valve - N280- is switched over to internal lubrication  
via a valve if the refrigerant circuit is empty.  
Depending on the version of air conditioner compressor, a  
valve may be installed on the high-pressure side that prevents  
liquefied refrigerant flowing back into the air conditioner com‐  
pressor after the air conditioning system is switched off. If an  
air conditioner compressor with this valve is installed in a ve‐  
hicle with a refrigerant circuit with expansion valve, it could  
take some time before the pressure on the high-pressure side  
drops (the expansion valve is cold and the pressure on the  
low-pressure side rises quickly after switching off, the expan‐  
sion valve closes and refrigerant only flows slowly on the low-  
pressure side). If the air conditioner compressor is switched  
on, the pressure on the low-pressure side drops, the expan‐  
sion valve opens and refrigerant can flow on the low-pressure  
side.  
1. Refrigerant circuit  
39  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
On an air conditioner compressor with electromagnetic clutch  
-A- and regulating valve -C-, the electromagnetic clutch -A- is  
usually only actuated if the regulating valve -C- is also actu‐  
ated ⇒ Heating, air conditioning system; Rep. gr. 87 ; Refrig‐  
erant circuit .  
1.2.3  
Electrical air conditioner compressor for  
hybrid vehicles  
Vehicles with high-voltage system (hybrid vehicles)  
If repair work in the vicinity of high-voltage components and ca‐  
bles is necessary, inspect high-voltage components and cables  
for damage ⇒ page 4 ⇒ Electrical system; Rep. gr. 93 ; General  
warnings for work on the high-voltage system .  
If work on the components of the high-voltage system is neces‐  
sary, ensure that the high-voltage system is de-energised ⇒ Rep.  
gr. 93 ; De-energising high-voltage system .  
De-energise the high-voltage system and restarting the high-volt‐  
age system ⇒ Rep. gr. 93 ; De-energising high-voltage system  
– To minimise the number of automatic engine starts when the  
vehicle's drive system is active (READY) during test and  
measurement work, charge the vehicle batteries e.g. with the  
battery charger 60 A - VAS 5904- in battery standby mode ⇒  
Electrical system - General information; Rep. gr. 27 ; Charging  
battery and ⇒ Electrical system; Rep. gr. 93 ; General warn‐  
ings for work on the high-voltage system .  
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40  
Rep. gr.87 - Air conditioning system  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
– For testing and measuring work that requires the vehicle's  
drive system to be active (READY) or the ignition to be switch‐  
ed on, move the selector lever to position “P”, activate the  
parking brake, and arrange the tools needed so that they can‐  
not come into contact with moving components of the engine  
and so that they cannot even come near to components that  
turn when the engine is running.  
Electrical air conditioner compressor  
NOTICE  
Risk of irreparable damage to electrical air conditioner com‐  
pressor from short circuit.  
– Never touch the air conditioner compressor when switching  
on the ignition or starting the drive machines.  
♦ The air conditioner compressor draws refrigerant gas from the  
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evaporator, compresses it and sends it to the condenser.  
♦ The electric motor of the air conditioner compressor is sup‐  
plied with power e.g. from the power and control electronics  
for electric drive - JX1- ⇒ Current flow diagrams, Electrical fault  
finding and Fitting locations.  
♦ The control unit for air conditioner compressor - J842- inte‐  
grated in the air conditioner compressor regulates the speed  
and thereby the performance of the air conditioner compressor  
( electrical air conditioner compressor - V470- ) according to  
the request received via the data bus ⇒ Vehicle diagnostic  
tester in “Guided Fault Finding” function of air conditioning  
system and battery control system  
♦ There is no air conditioner compressor regulating valve -  
N280- in the electrical air conditioner compressor.  
♦ The bolting points of the air conditioner compressor and the  
bracket must be checked prior to installation. The contact sur‐  
faces must be free of dirt, rust and grease. Otherwise, repair  
contact surfaces using contact surface cleaning set - VAS  
6410- ⇒ Electrical system; General information; Rep. gr. 97 ;  
Wiring harness and connector repair .  
1. Refrigerant circuit  
41  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
Note  
If the air conditioner compressor control unit - J842- is defec‐  
tive, the amount of refrigerant oil in the new air conditioner  
compressor must be adjusted. The refrigerant circuit must not  
be cleaned (flushed) with R1234yf.  
The control unit for air conditioner compressor - J842- and the  
electrical air conditioner compressor - V470- are one compo‐  
nent and can currently not be separated.  
There is no -N280- installed in the electrical air conditioner  
compressor. The power of the air conditioner compressor is  
regulated externally by the speed of the air conditioner com‐  
pressor ⇒ Current flow diagrams, Electrical fault finding and  
Fitting locations and ⇒ Vehicle diagnostic tester in “Guided  
Fault Finding” mode - air conditioning system and battery reg‐  
ulation.  
The electrical air conditioner compressor currently works in  
the same way as a spiral or scroll-type charger (similar to a G-  
Lader).  
The air conditioner compressor contains refrigerant oil, which  
can be mixed with R1234yf refrigerant at any temperature.  
The identification plate states the refrigerant for which the air  
conditioner compressor is suitable.  
The integrated electronics regulate the performance of the air  
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conditioner compressor via the speed (and thereby the pres‐  
sure on the low-pressure side) within the specific target range  
(control characteristic).  
The engine should be started only when the refrigerant circuit  
has been fully assembled.  
The air conditioner compressor has an internal oil circuit to  
ensure that the air conditioner compressor is not damaged  
when the refrigerant circuit is empty. This means that approx.  
40 to 50 cm3 of refrigerant oil remain in the air conditioner  
compressor.  
Just like the mechanical air conditioner compressor, the elec‐  
trical air conditioner compressor has a pressure relief valve.  
On vehicles with battery cooling, electric and hybrid operation  
is only possible with the air conditioning system charged and  
no faults stored in connection with the air conditioning system  
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode -  
air conditioning system and battery regulation.  
First bring the electrical air conditioner compressor into oper‐  
ation after installing the air conditioner compressor and charg‐  
ing the refrigerant circuit via the “Compressor run-in” function  
in basic settings. Should there be an accumulation of refriger‐  
ant oil in the compression chamber of the air conditioner  
compressor before installation owing to unfavourable storage,  
damage could be caused to the air conditioner compressor  
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode -  
air conditioning system and battery regulation.  
An electrically driven air conditioner compressor may only be  
activated when the refrigerant circuit is charged. Running the  
air conditioner compressor with the refrigerant circuit empty  
could lead to compressor damage ⇒ Vehicle diagnostic tester  
in “Guided Fault Finding” mode.  
42  
Rep. gr.87 - Air conditioning system  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
1.2.4  
Condenser  
♦ The condenser -A- transfers heat from the compressed refrig‐  
erant gas into the surrounding air.  
♦ When this happens, the refrigerant gas condenses to liquid.  
Note  
Depending on the design of the refrigerant circuit, the receiver  
may be attached to the condenser or integrated in the con‐  
denser ⇒ Heating, air conditioning system; Rep. gr. 87 ;  
Refrigerant circuit (vehicle-specific workshop manual) and ⇒  
Electronic parts catalogue .  
There are different versions of the condenser; from the outside  
these versions can only be identified by their part number.  
Version -1- of the condenser is split into two sections (“two-  
pass condenser”). Version -2- of the condenser is split into four  
sections (“four-pass condenser”).  
This illustration shows a condenser with the receiver -C- at‐  
tached.  
The gaseous refrigerant enters the condenser at connection  
-A-; the refrigerant is then cooled down in the condenser and  
turns into liquid.  
The liquid refrigerant accumulates in receiver -C- (with dryer)  
and flows through the bottom cooling section to connection  
-B-.  
The refrigerant capacity in a refrigerant circuit may differ de‐  
pending on the design of the condenser (internal volume, flow,  
etc.). Therefore, always ensure the version and allocation of  
the condenser are correct ⇒ Heating, air conditioning system;  
Rep. gr. 00 ; Technical data (vehicle-specific workshop man‐  
ual) and ⇒ Electronic parts catalogue .  
1.2.5  
Evaporator  
There are different types of evaporator. Depending on the design  
and function, the thermal energy that is needed to evaporate the  
refrigerant is drawn from the air flowing through the system (e.g.  
with the evaporator in heater and air conditioning unit or in the  
battery cooling module) or the coolant flowing through the system  
(e.g. with the heat exchanger for the high-voltage battery) ⇒  
Heating, air conditioning system; Rep. gr. 87 ; Refrigerant circuit;  
System overview - refrigerant circuit (vehicle-specific workshop  
manual).  
Note  
The following describes 2 versions of the evaporator.  
1. Refrigerant circuit  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
Evaporator in heating and air conditioning system (or in the bat‐  
tery cooling module)  
♦ The liquid refrigerant evaporates in the pipelines of the evap‐  
orator -A-. The heat required to do this is drawn from the air  
flowing over the evaporator fins -B-. The air cools down. The  
refrigerant evaporates and is drawn into the air conditioning  
system compressor carrying with it the heat it has absorbed.  
♦ A defined quantity of refrigerant is fed to the evaporator  
through an expansion valve (restrictor). In systems with an  
expansion valve the flow rate is regulated such that only gas‐  
eous refrigerant emerges at the evaporator outlet.  
♦ When R1234yf refrigerant was introduced, the evaporators  
were adapted to the refrigerant, hence the need to observe the  
correct version ⇒ Electronic parts catalogue .  
Evaporator / heat exchanger for high-voltage battery (chiller)  
The liquid refrigerant evaporates in the evaporator (heat ex‐  
changer). The heat required to do this is drawn from the coolant  
that flows through the evaporator. The coolant cools. The refrig‐  
erant evaporates and is drawn into the air conditioner compressor  
carrying with it the heat it has absorbed.  
A defined quantity of refrigerant is fed to the evaporator through  
a restrictor (or an expansion valve) and a shut-off valve. The flow  
rate of the coolant (or refrigerant) is regulated in such a way that  
only gaseous refrigerant escapes at the evaporator outlet ⇒  
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System  
overview - refrigerant circuit (vehicle-specific workshop manual).  
1.2.6  
Reservoir  
lk  
Note  
This type of air conditioning system is currently only installed in  
systems with a restrictor.  
44  
Rep. gr.87 - Air conditioning system  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
♦ The reservoir collects the vaporised and gaseous mixture  
coming from the evaporator to ensure the air conditioner com‐  
lk  
pressor receives only gaseous refrigerant. The vapour be‐  
comes gaseous refrigerant.  
♦ Refrigerant oil flowing in the circuit does not remain in the res‐  
ervoir because an oil extraction hole has been provided.  
♦ Any moisture ingress into the refrigerant circuit during assem‐  
bly is trapped by a filter (desiccant bag) in the reservoir.  
♦ Gaseous refrigerant with oil is drawn in by the air conditioner  
compressor.  
Note  
Renew the reservoir if the refrigerant circuit has been open for  
an extended period of time and moisture has entered or if re‐  
quired to do so owing to a specific complaint ⇒ page 79 .  
Do not remove sealing plugs -A- and -B- until just before in‐  
stallation.  
A dryer kept in an unsealed reservoir is saturated with mois‐  
ture after a short time and cannot be used.  
When installing, observe arrow indicating direction of flow if  
applicable.  
1.2.7  
Heat exchanger for heat pump mode  
The gaseous or vaporous refrigerant compressed by the air con‐  
ditioning compressor is liquefied in the heat exchanger -A-. The  
heat that is given off in the process is picked-up by the coolant  
flowing through the system ⇒ Heating, air conditioning; Rep. gr.  
87 ; Refrigerant circuit; System overview - refrigerant circuit .  
1.2.8  
Liquid receiver  
In certain operating conditions (e.g. in heat pump mode), the re‐  
ceiver (e.g. on the condenser) is not integrated in the refrigerant  
circuit. The receiver -B- collects the refrigerant, temporarily stores  
any excess should a certain amount of refrigerant not be required  
and then feeds it in a steady flow to the expansion valve (in front  
of the evaporator in the heater and air conditioning unit) or to the  
heat exchanger in the coolant circuit of the high voltage system  
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; Sys‐  
tem overview - refrigerant circuit .  
1. Refrigerant circuit  
45  
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1.2.9  
Restrictor  
Restrictor in front of evaporator  
Note  
Currently, there is no air conditioning system with a restrictor in‐  
stalled in front of the evaporator.  
lk  
♦ The restrictor creates a constriction. This restriction limits the  
flow, separating the high pressure and low pressure sides in  
the refrigerant circuit. Upstream of the restrictor, the refriger‐  
ant is warm due to the high pressure. Downstream of the  
restrictor, the refrigerant is cold due to the low pressure. Up‐  
stream of the constriction is a strainer to catch dirt and down‐  
stream of the constriction is a strainer to atomise the  
refrigerant before it enters the evaporator.  
Note  
Arrow -A- on the restrictor points to the evaporator.  
Renew every time the refrigerant circuit is opened.  
Note different versions; refer to the various customer service  
information ⇒ Electronic parts catalogue .  
Restrictor in front of heat exchanger for high-voltage battery (chill‐  
er)  
The restrictor creates a constriction. This restriction limits the flow,  
separating the high pressure and low pressure sides in the re‐  
frigerant circuit. Upstream of the restrictor, the refrigerant is warm  
due to the high pressure. Downstream of the restrictor, the refrig‐  
erant is cold due to the low pressure.  
Note  
The illustration shows a refrigerant line -A- with a permanently  
installed restrictor -B- (without strainer).  
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.  
Check for soiling before installing and clean or renew as nec‐  
essary.  
Observe different versions.  
46  
Rep. gr.87 - Air conditioning system  
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1.2.10  
Receiver  
♦ The receiver -B- collects the liquid droplets and directs them  
in a continuous stream to the expansion valve. Any moisture  
that has entered the refrigerant circuit during assembly is col‐  
lected by a dryer -D- in the receiver -B-.  
♦ Depending on the layout of the refrigerant circuit and the ver‐  
sion of condenser -A-, the receiver -B- may be installed on the  
condenser -A- or (integrated) in the condenser -A- ⇒ Heating,  
air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-spe‐  
cific workshop manual) and ⇒ Electronic parts catalogue .  
♦ Installed in the receiver -B- is a dryer (e.g. desiccant bag -D-)  
and strainer -F- (that filters out smaller contaminants).  
Note  
The receiver -B- comes in different versions and different de‐  
signs ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant  
circuit (vehicle-specific workshop manual) and ⇒ Electronic  
parts catalogue .  
Renew the receiver -B- and plastic bolt (with seals) -C-, des‐  
iccant cartridge -D-, filter carrier -E- and strainer -F- if the  
refrigerant circuit was open for an extended period of time and  
moisture has been absorbed, or if required to do so owing to  
a specific complaint ⇒ page 79 .  
Do not remove the sealing plugs of a receiver until immediately  
prior to installation as a desiccant bag in a non-sealed reser‐  
voir will become saturated with moisture and become unusa‐  
ble.  
The desiccant cartridge comes in an air-tight transport bag,  
which should remain sealed for as long as possible. Do not  
open the transport bag until immediately prior to inserting the  
desiccant cartridge -D- in the receiver -B- of the condenser.  
After the transport bag has been opened, the desiccant car‐  
tridge will become saturated with moisture within a short time  
and is then unusable.  
When installing, observe arrow indicating direction of flow if  
applicable.  
The procedure to adopt in the event of a complaint differs de‐  
pending on the type of receiver/desiccant cartridge. If the  
receiver is installed on the condenser, for example, it can be  
renewed completely with the desiccant cartridge. If the receiv‐  
er is integrated in the condenser, for example, the desiccant  
cartridge and an additional filter element (if one is fitted) can  
be replaced individually on most versions. If the receiver is  
integrated in the condenser and it is not possible to replace  
the receiver/desiccant cartridge separately, it may be neces‐  
sary to replace the entire condenser ⇒ Heating, air condition‐  
ing; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop  
manual) and ⇒ Electronic parts catalogue .  
Depending on the layout of the refrigerant circuit (with desic‐  
cant bag or desiccant cartridge), the receiver may also be  
integrated in the refrigerant circuit (it need not always be in‐  
stalled on or in the condenser) ⇒ Heating, air conditioning;  
Rep. gr. 87 ; Refrigerant circuit (vehicle-specific workshop  
manual) and ⇒ Electronic parts catalogue .  
1. Refrigerant circuit  
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1.2.11  
Expansion valve (with and without shut-  
off valve)  
Expansion valve without shut-off function  
The expansion valve -A- atomises incoming refrigerant and reg‐  
ulates the flow so that, depending on the heat transport, the  
vapour does not become a gas until it reaches the outlet of the  
evaporator.  
Note  
When R1234yf refrigerant was introduced, the expansion  
valves were adapted to the refrigerant (different characteris‐  
tics), hence the need to observe the correct version ⇒ Elec‐  
tronic parts catalogue .  
Different versions of expansion valve due to different charac‐  
teristics that are matched to the relevant refrigerant circuit ⇒  
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (ve‐  
hicle-specific workshop manual) and ⇒ Electronic parts cata‐  
lk  
logue .  
When renewing the expansion valve, make sure that the part  
number is correct ⇒ Electronic parts catalogue .  
Depending on the version of air conditioner compressor, a  
valve may be installed on the high-pressure side that prevents  
liquefied refrigerant flowing back into the air conditioner com‐  
pressor after the air conditioning system is switched off. If an  
air conditioner compressor with this valve is installed in a ve‐  
hicle with a refrigerant circuit with expansion valve, it could  
take some time before the pressure on the high-pressure side  
drops (the expansion valve is cold and the pressure on the  
low-pressure side rises quickly after switching off, the expan‐  
sion valve closes and refrigerant only flows slowly on the low-  
pressure side). If the air conditioner compressor is switched  
on, the pressure on the low-pressure side drops, the expan‐  
sion valve opens and refrigerant can flow on the low-pressure  
side.  
Expansion valve with refrigerant shut-off valve  
Note  
Shut-off valves come in different versions, with different functions  
and different designations ⇒ Heating, air conditioning; Rep. gr.  
87 ; Refrigerant circuit (vehicle-specific workshop manual).  
48  
Rep. gr.87 - Air conditioning system  
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♦ The expansion valve -A- with shut-off valve -B- atomises the  
incoming refrigerant and regulates the flow rate of the refrig‐  
erant to the evaporator in the battery cooling module of the  
hybrid battery unit - AX1- in such a way that, depending on the  
heat transport, the vapour does not become a gas until it rea‐  
ches the outlet of the evaporator.  
♦ If the shut-off valve -B- is actuated by the electronics, it is open  
and allows refrigerant to flow through to the expansion valve  
-A-.  
♦ If the shut-off valve -B- is open, the expansion valve -A- allows  
refrigerant to flow through to the evaporator or heat exchanger  
based on its control characteristic ⇒ Heating, air conditioning;  
Rep. gr. 87 ; Refrigerant circuit .  
♦ The solenoid -B- attached to the expansion valve -A- is actu‐  
ated by different control units depending on the vehicle ⇒ Cur‐  
rent flow diagrams, Electrical fault finding and Fitting locations  
and ⇒ Vehicle diagnostic tester in “Guided Fault Finding”  
mode.  
♦ If, on a vehicle with 2 evaporators (one in the heater and air  
conditioner unit and one in the battery cooling module, e.g. the  
Audi Q5 Hybrid), the temperature measured at one evaporator  
meets the specification or falls below the specification, while  
on the other evaporator however the requisite specification is  
not reached, regulation works as follows: the battery regula‐  
lk  
tion control unit - J840- makes the electrical air conditioner  
compressor run at a higher speed via the power and control  
electronics for electric drive - JX1- and the control unit for air  
conditioning compressor - J842- (which results in the cooling  
output of the air conditioning system rising and pressure on  
the low pressure side falling along with the evaporator tem‐  
perature). If, as a result, the temperature at one evaporator  
falls below the specified level, -J840- actuates refrigerant shut-  
off valve 1 for hybrid battery - N516- or refrigerant shut-off  
valve 2 for hybrid battery - N517- in such a way that the evap‐  
orator - which is too cold - no longer has refrigerant flowing  
through it ⇒ Vehicle diagnostic tester in “Guided Fault Finding”  
mode.  
1. Refrigerant circuit  
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1.2.12  
Refrigerant shut-off valves  
Shut-off valves with 2 switch statuses (open or closed)  
♦ Shut-off valves come in different versions, with different func‐  
tions and different designations ⇒ Heating, air conditioning;  
Rep. gr. 87 ; Refrigerant circuit .  
♦ If the shut-off valve -A- is not actuated by the electronics, it is  
open and allows refrigerant to flow through.  
♦ The shut-off valve -A- is installed on vehicles with high-voltage  
system, for example. It is actuated when no climate control is  
wanted for the passenger compartment but battery cooling is  
required for the hybrid battery unit - AX1- .  
♦ Note the arrow -B- on the shut-off valve -A-, which shows the  
direction of refrigerant flow (from condenser to evaporator in  
the heater and air conditioning unit).  
♦ The solenoid -C- attached to the shut-off valve -A- is actuated  
by different control units depending on the vehicle ⇒ Current  
flow diagrams, Electrical fault finding and Fitting locations and  
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode -  
air conditioning system and battery regulation.  
♦ If, on a vehicle with 2 evaporators (one in the heater and air  
conditioner unit and one in the battery cooling module, e.g. the  
Audi Q5 Hybrid), the temperature measured at one evaporator  
meets the specification or falls below the specification, while  
on the other evaporator however the requisite specification is  
not reached, regulation works as follows: the respective con‐  
trol unit makes the electrical air conditioner compressor run at  
a higher speed (which results in the cooling output of the air  
conditioning system rising and pressure on the low pressure  
side falling along with the evaporator temperature). If the tem‐  
perature at an evaporator then falls below the specified level,  
the respective control unit actuates the shut-off valve in such  
lk  
a way that the evaporator that is too cold no longer has refrig‐  
erant flowing through it ⇒ Heating, air conditioning; Rep. gr.  
87 ; Refrigerant circuit and ⇒ Vehicle diagnostic tester in “Gui‐  
ded Fault Finding” mode.  
Shut-off valves regulated via characteristic curves  
♦ The shut-off valve -A- is actuated via an incremental motor  
-B- by the respective control unit with characteristic curves  
(open or closed).  
♦ If the shut-off valve acts as a control valve (e.g. refrigerant  
expansion valve 1 - N636- as is the case with the Audi Q7), it  
is only opened enough to allow the temperature set for the heat  
exchanger to be reached ⇒ Heating, air conditioning; Rep. gr.  
87 ; Refrigerant circuit .  
♦ Shut-off valves actuated via incremental motors do not have  
a defined rest position. For this reason, they have to be set to  
a certain position (open or closed) before work on the refrig‐  
erant circuit is performed ⇒ Heating, air conditioning; Rep. gr.  
87 ; Refrigerant circuit .  
♦ Depending on layout of the refrigerant circuit there could be a  
cluster of shut-off valves forming a valve block (e.g. on the e-  
Golf or Audi Q7 e-tron) ⇒ Heating, air conditioning; Rep. gr.  
87 ; Refrigerant circuit .  
♦ The incremental motor is programmed and actuated via data  
lines (LIN-Bus) by the respective control unit in relation to its  
installation location ⇒ Heating, air conditioning; Rep. gr. 87 ;  
Refrigerant circuit and ⇒ Vehicle diagnostic tester in “Guided  
Fault Finding” mode.  
50  
Rep. gr.87 - Air conditioning system  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
1.2.13  
Refrigerant line with internal heat ex‐  
changer  
♦ In this refrigerant line, the warm liquid refrigerant flowing on  
the high pressure side supplies energy to the cold refrigerant  
gas or vapour flowing on the low pressure side, thus enhanc‐  
ing the efficiency of the air conditioner.  
Note  
This illustration shows a refrigerant line with inner heat exchanger  
as fitted e.g. on the Golf 7, Audi A4 2008 > and Audi A5 Coupé  
2008 > ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant  
circuit .  
A - Refrigerant line with internal heat exchanger  
B - Channels in the refrigerant line along which hot liquid refrig‐  
erant flows to the evaporator (high pressure side of refrigerant  
circuit).  
C - Channel in the refrigerant line through which the cold gaseous  
or vaporous refrigerant flows to the air conditioner compressor  
(low pressure side of refrigerant circuit).  
1.2.14  
Quick release couplings of refrigerant  
lines  
Note  
This illustration shows the quick-release couplings with a re‐  
frigerant line with internal heat exchanger as fitted e.g. on the  
Audi A4 2008 > and the Audi A5 Coupé 2008 > ⇒ Heating, air  
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific  
workshop manual).  
Removal of the refrigerant line -D- involves opening the re‐  
taining ring -A- e.g. with the refrigerant line release tool ( re‐  
lease tool - T40149- or removal tool - T40232- ) ⇒ Heating,  
air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-spe‐  
cific workshop manual).  
After removing the respective refrigerant line, the quick re‐  
lease couplings -B- and -G- are to be renewed along with the  
associated support ring -E- or -H- and the associated seal  
-F- or -J- ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant  
circuit (vehicle-specific workshop manual) and ⇒ Electronic  
parts catalogue .  
A - Retaining ring (in quick release coupling on high pressure  
side)  
B - Quick release coupling with retaining ring “high pressure side”  
C - Refrigerant line with internal heat exchanger  
D - Refrigerant line “high pressure side”  
E - Support ring “high pressure side”  
F - Seal “high pressure side”  
G - Quick release coupling with retaining ring “low pressure side”  
H - Support ring “low pressure side”  
J - Seal “low pressure side”  
1. Refrigerant circuit  
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Note  
The quick release couplings come in different versions -A- and  
-D-. On both versions of these quick release couplings, the  
refrigerant lines -C- can be released and removed in the same  
way, e.g. with refrigerant line release tool -T40149/1- ⇒ Heat‐  
ing, air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-  
specific workshop manual).  
For quick release coupling version -A-, the control pins -B- be‐  
come visible after installing the refrigerant line -C- once the  
engaged refrigerant line -C- is pulled in the direction of arrow.  
For quick release coupling version -D-, the refrigerant line  
-C- is installed in the same way as quick release coupling  
-A-. When the refrigerant line -C- on this version is pulled in  
the direction of arrow following assembly, the snap ring -E-  
protrudes from the quick release coupling -D-, thereby indi‐  
cating that the retaining ring -F- is completely engaged with  
the refrigerant line -C-. The snap ring -E- must then be re‐  
moved from the refrigerant line -C-.  
1.2.15  
Seals  
♦ These seals seal the connection points between the individual  
components of the refrigerant circuit  
⇒ “3.2 Refrigerant circuit seals”, page 8 .  
1.2.16  
Pipes and hoses in refrigerant circuit  
♦ In its pure state, R1234yf refrigerant is chemically stable and  
has no corrosive effect on e.g. iron, aluminium and specially  
developed plastics that are suitable for this purpose. A mixture  
of refrigerant oil and R1234yf refrigerant can affect certain  
metals (e.g. alloys with copper) and affect or degrade certain  
hose materials and plastics. Therefore, use only genuine re‐  
placement parts ⇒ Electronic parts catalogue .  
♦ Only use components that are resistant to R1234yf refrigerant  
and its associated refrigerant oils. Do not use components  
(such as seals and hoses, which are made of plastic) that  
cannot be clearly allocated ⇒ Electronic parts catalogue .  
♦ The pipes and hoses are held together by threaded connec‐  
tions and / or special joints ⇒ Heating, air conditioning; Rep.  
gr. 87 ; Refrigerant circuit (vehicle-specific workshop manual).  
♦ Renew the sealing elements (e.g. seals) between the compo‐  
nents ⇒ Electronic parts catalogue .  
♦ For threaded connections, observe the specified torque set‐  
tings. For pressure-fit connections, use dedicated release  
tools ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant  
circuit (vehicle-specific workshop manual).  
52  
Rep. gr.87 - Air conditioning system  
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1.2.17  
High-pressure safety valve  
The high pressure safety valve is fitted to the air conditioner com‐  
pressor or the receiver.  
The valve opens at a pressure of approx. 38 bar (overpressure)  
and closes again when the pressure has dropped (to approx. 35  
bar).  
Not all the refrigerant is lost from the system.  
Note  
Depending on the version, a transparent plastic washer -B-  
may be attached to the high pressure safety valve -A- which  
breaks off as soon as the valve is actuated.  
Depending on the version of high pressure safety valve -A-, a  
cover -C- may also be pushed onto the high pressure safety  
valve -A-. Should the pressure in the refrigerant circuit actually  
rise above the opening pressure of the high pressure safety  
valve -A- and cause the valve to open, refrigerant will not es‐  
cape in one direction but scatter through the openings -D-  
beneath the cover -C- instead.  
If a high-pressure safety valve -A- needs to be renewed, the  
specified torque for the new valve (depending on the manu‐  
facturer and the version of the air conditioner compressor)  
must be observed when installing. Air conditioner compres‐  
sors manufactured by “Denso”, “Sanden” and “Valeo” are  
equipped with an O-ring seal (currently valid torque settings  
are: 10 Nm for “Denso” and “Zexel/Valeo” air conditioner com‐  
pressors, and 15 Nm for “Sanden” air conditioner compres‐  
sors). Air conditioner compressors manufactured by “Delphi”  
are fitted with an oil seal (currently valid torque setting: 15 Nm).  
lk  
Renewing seals (oil seals or O-rings) ⇒ Electronic parts cata‐  
logue .  
If a seal (oil seal or O-ring) fitted to the high-pressure safety  
valve is not available as a replacement part, the removed old  
part can be reused (as an exception to the general rule of using  
new seals only). The old seal, however, must always be  
checked for damage prior to installation. If any damage or de‐  
formation is detected on the old seal, it must be renewed with  
a commercially available new part ⇒ Electronic parts cata‐  
logue .  
After filling the refrigerant circuit, check the installed high-  
pressure safety valve for leaks using e.g. an electronic leak  
detector.  
1. Refrigerant circuit  
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1.2.18  
Non-return valves  
Non-return valves separate the refrigerant circuit into different  
areas ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit  
(vehicle-specific workshop manual).  
Note  
The non-return valve -3- shown in installed e.g. in the Audi Q7  
e-tron ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant  
circuit (vehicle-specific workshop manual).  
Non-return valves in the refrigerant circuit have a certain hold‐  
ing pressure in the direction of flow (approx. 0.1 bar or  
100 mbar). To ensure that the refrigerant circuit can be evac‐  
uated completely (residual pressure below 5 mbar), all of the  
electrically actuated valves must therefore be open.  
Depending on the version, the direction of flow may be indi‐  
cated by a sticker.  
lk  
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Rep. gr.87 - Air conditioning system  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
1.2.19  
Quick-release coupling connections in  
refrigerant circuit  
Service connections with Schrader valve (needle valve or push  
pin)  
♦ Only valves and connections resistant to R1234yf refrigerant  
and the related refrigerant oils may be used.  
♦ Service connections -C- and -F- in an R1234yf refrigerant cir‐  
cuit are configured in such a way that service couplings cannot  
be connected to service connections designed for an R134a  
refrigerant circuit.  
♦ Different connections (external diameter) for high pressure  
and low pressure side -C- and -F-.  
♦ Before removing the valves or valve inserts -B- and -E-, empty  
the refrigerant circuit.  
♦ Always screw on sealing caps -A- and -D- with seal -G-.  
Layout in vehicle ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐  
frigerant circuit (vehicle-specific workshop manual).  
– Extract refrigerant before unscrewing the valves.  
♦ Service connection, low pressure side -F-  
♦ Service connection, high pressure side -C-  
♦ Valve insert (designation: Schrader or needle valve)  
♦ Sealing cap for service connection on low pressure side with  
seal -A-  
♦ Sealing cap for service connection on high pressure side with  
seal -D-  
lk  
1. Refrigerant circuit  
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Note  
Carefully, and no more than necessary, screw in the hand‐  
wheel of the service coupling (after connecting) into the quick  
release coupling adapter until the valve in the service connec‐  
tion is open (observe pressure gauge; do not over-tighten  
valve).  
Service connections in an R1234yf refrigerant circuit are con‐  
figured in such a way that service couplings cannot be con‐  
nected to service connections designed for an R134a  
refrigerant circuit.  
The service connections are brazed into e.g. a refrigerant line  
and therefore cannot be replaced individually.  
lk  
When removing and installing valve core with refrigerant cir‐  
cuit discharged, use a socket - T10364- or similar.  
Exercise caution when tightening the valve insert due to the  
low tightening torque.  
There are different versions of these valves; therefore tight‐  
ening torques vary. For a valve insert -C- with a VG5 thread  
(5.2 x 0.7 mm, tyre valve) the tightening torque is 0.4 Nm  
± 0.1 Nm; for a valve insert with an M6 x 0.75 mm thread the  
tightening torque is 0.9 Nm ± 0.1 Nm, and for a valve insert  
with an M8 x 1.0 mm thread the tightening torque is  
2.0 Nm ± 0.2 Nm.  
These valve caps come in different versions, which means that  
the specified torques will differ. For a valve cap with an M8 x  
1 mm or M10 x 1 mm thread, the specified torque is  
0.4 Nm ± 0.1 Nm respectively.  
These valves, valve inserts and corresponding sealing caps  
come in different versions. Make sure that the correct type of  
valve insert is used and allocation of the sealing caps is correct  
⇒ Electronic parts catalogue .  
Dimensions of service connections  
56  
Rep. gr.87 - Air conditioning system  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
♦ Valve insert -A- (different versions).  
♦ Service connection -B- (different versions on high pressure  
and low pressure side depending on refrigerant)  
Dimensions of serv‐ Service connec‐  
Service connection  
ice connections -B- tion for R134a re‐ for R1234yf refriger‐  
frigerant  
High-  
ant  
Low-  
High-  
Low-  
pressure pres‐  
pressure pressure  
side  
sure  
side  
side  
side  
External diameter  
-D1-  
16.0 mm 13.0 m 17.0 mm 14.0 mm  
m
External diameter  
14.0 mm 11.0 m 13.0 mm 12.0 mm  
m
-D2-  
Shoulder -L1-  
Shoulder -L2-  
4.6 mm 6.15 m 9.0 mm 4.75 mm  
m
8.16 mm 9.16 m 12.5 mm 7.2 mm  
m
Installation position of 6.1 - 7.1 6.1 - 7.1 8.3 - 9.3 8.3 - 9.3  
valve (unactuated)  
-C-  
mm  
mm  
mm  
mm  
Service connections with primary sealing valve (ball valve)  
♦ This type of service connection is currently not used in VW/  
Audi refrigerant circuits.  
♦ Only valves and connections resistant to R1234yf refrigerant  
and the related refrigerant oils may be used.  
♦ Service connections in an R1234yf refrigerant circuit are con‐  
figured in such a way that service couplings cannot be con‐  
nected to service connections designed for an R134a  
refrigerant circuit.  
♦ Different connections (external diameter) for high-pressure  
and low-pressure sides.  
♦ Discharge refrigerant circuit before removing valve or valve  
inserts.  
♦ Always screw on sealing caps with seal.  
Layout in vehicle ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐  
frigerant circuit (vehicle-specific workshop manual).  
1. Refrigerant circuit  
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Connection with high pressure valve  
1 - Boss with internal thread (brazed on)  
2 - Seal (version and designation: black or coloured ⇒ Elec‐  
tronic parts catalogue )  
3 - Valve with external thread and groove for seal (designation:  
ball valve)  
4 - Seal for sealing cap  
5 - Sealing cap  
Note  
Carefully, and no more than necessary, screw in the hand‐  
wheel of the service coupling (after connecting) into the quick  
release coupling adapter until the valve in the service connec‐  
tion is open (observe pressure gauge; do not over-tighten  
valve).  
When removing and installing the valve -3- with purged refrig‐  
erant circuit, use e.g. an adapter from socket set - T10364- .  
These valves come in different versions (with internal or ex‐  
ternal thread) and the specified torques can therefore differ.  
For the valves -3- currently in use (external thread M12 x 1.5  
mm) the tightening torque is 9 Nm ± 1 Nm.  
These valves and corresponding sealing caps come in differ‐  
ent versions. Make sure that the correct type of valve is used  
and allocation of the sealing caps is correct ⇒ Electronic parts  
catalogue .  
Connection with low pressure valve  
lk  
1 - Boss with external thread and groove for O-ring (brazed in)  
2 - Seal (version and designation: black or coloured ⇒ Elec‐  
tronic parts catalogue )  
3 - Valve with internal thread  
4 - Seal for sealing cap  
5 - Sealing cap  
Note  
Carefully, and no more than necessary, screw in the hand‐  
wheel of the service coupling into the quick release coupling  
adapter until the valve in the service connection is open (ob‐  
serve pressure gauge; do not over-tighten valve).  
When removing and installing the valve -3- with purged refrig‐  
erant circuit, use e.g. an adapter from socket set - T10364- .  
These valves come in different versions (with internal or ex‐  
ternal thread) and the specified torques can therefore differ.  
For the valves -3- currently in use (internal thread  
M10 x 1.25 mm) the tightening torque is 9 Nm ± 1 Nm.  
These valves and corresponding sealing caps come in differ‐  
ent versions. Make sure that the correct type of valve is used  
and allocation of the sealing caps is correct ⇒ Electronic parts  
catalogue .  
58  
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1.2.20  
Connections with valve for switches in  
refrigerant circuit  
Note  
Refer to vehicle-specific refrigerant circuit for switching pres‐  
sures, removing and installing switches and location/design of  
switches ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant  
circuit (vehicle-specific workshop manual).  
The switches on the high pressure and low pressure sides  
have different threads.  
Only valves and seals resistant to R1234yf refrigerant and the  
related refrigerant oils may be used ⇒ Electronic parts cata‐  
logue .  
A - Connection (brazed)  
B - Seal  
C - Valve (with seal)  
lk  
Note  
To remove and install the valve -C- with the refrigerant circuit  
empty, use e.g. an adapter from socket set - T10364- (speci‐  
fied torque ⇒ page 55 ).  
There are different versions of these valves; therefore tight‐  
ening torques vary. For a valve insert -C- with a VG5 thread  
(5.2 x 0.7 mm, tyre valve) the tightening torque is 0.4 Nm  
± 0.1 Nm; for a valve insert with an M6 x 0.75 mm thread the  
tightening torque is 0.9 Nm ± 0.1 Nm, and for a valve insert  
with an M8 x 1.0 mm thread the tightening torque is  
2.0 Nm ± 0.2 Nm.  
1.2.21  
Pressure senders and switches in refrig‐  
erant circuit  
Note  
Pressure senders and switches come in different versions,  
with different functions and different designations ⇒ Heating,  
air conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-spe‐  
cific workshop manual).  
Switching pressures, removing and installing switches and  
switch layout and type ⇒ Heating, air conditioning; Rep. gr.  
87 ; Refrigerant circuit (vehicle-specific workshop manual).  
1. Refrigerant circuit  
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♦ The high pressure sender shown is installed e.g. in the Golf 7  
and Audi A3 ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐  
frigerant circuit (vehicle-specific workshop manual).  
♦ One version of pressure sender generates a square-wave sig‐  
nal when voltage is applied. This signal changes with the  
pressure in the system. The other version of pressure sender  
exchanges information with the corresponding control unit via  
data bus (e.g. via the “LIN bus”) when voltage is applied ⇒ Cur‐  
rent flow diagrams, Electrical fault finding and Fitting locations  
and ⇒ Vehicle diagnostic tester in “Guided Fault Finding”  
mode - air conditioning system. Therefore, pay attention to the  
correct version of pressure sender.  
♦ The pressure senders come in different versions. Depending  
on the version, they can currently only be distinguished exter‐  
nally by the part number, which is why attention should be paid  
during renewal to their correct allocation (part number ⇒ Elec‐  
tronic parts catalogue ). Reason: These senders emit different  
lk  
signals, and the relevant control units can only evaluate the  
signal to which they have been matched ⇒ Vehicle diagnostic  
tester in “Guided Fault Finding” mode - air conditioning system  
and ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant cir‐  
cuit (vehicle-specific workshop manual).  
♦ One version of pressure sender only transmits the measured  
value for the pressure in the refrigerant circuit to the connected  
control unit. The other version transmits the measured value  
for the pressure in the refrigerant circuit and the measured  
temperature to the connected control unit, which is why atten‐  
tion should be paid to the correct version ⇒ Electronic parts  
catalogue .  
♦ With this signal, the downstream control units calculate the  
pressure in the refrigerant circuit and actuate the radiator fans  
and engine, the air conditioning system magnetic clutch - N25-  
accordingly or manipulate actuation of the air conditioner com‐  
pressor regulating valve - N280- ⇒ Vehicle diagnostic tester in  
“Guided Fault Finding” mode - air conditioning system and ⇒  
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (ve‐  
hicle-specific workshop manual).  
1.2.22  
Refrigerant pressure and temperature  
sender  
CAUTION  
Risk of freezing injury caused by escaping pressurised refrig‐  
erant.  
There is a risk of injury to the skin and parts of the body due to  
freezing.  
– Wear protective gloves.  
– Wear protective goggles.  
– Extract refrigerant and open the refrigerant circuit immedi‐  
ately afterwards.  
– If more than 10 minutes have passed since the refrigerant  
was extracted, repeat the extraction process before opening  
the refrigerant circuit. Pressure could build up in the refrig‐  
erant circuit from continued evaporation.  
60  
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Senders for connection to a refrigerant circuit with valve  
Note  
Refer to vehicle-specific refrigerant circuit for switching pres‐  
sures, removing and installing switches and location/design of  
switches ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant  
circuit (vehicle-specific workshop manual).  
These senders come in different versions, with different func‐  
tions and different designations. The refrigerant pressure and  
temperature sender - G395- shown as follows is installed e.g.  
in the Golf GTE, Audi A4, Audi Q5 and Audi Q5 Hybrid ⇒  
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;  
System overview - refrigerant circuit .  
Before loosening the threaded connection of the sender,  
check which version of sender it is ⇒ Heating, air conditioning;  
Rep. gr. 87 ; Refrigerant circuit; System overview - refrigerant  
circuit .  
For senders designed for connection to a refrigerant circuit  
without valve. The refrigerant must be extracted before the  
threaded connection is loosened. If the sender is not removed  
within 10 minutes after the system has been evacuated, pres‐  
sure may develop in the refrigerant circuit due to re-evapora‐  
tion. Extract refrigerant again.  
Different designations depending on the function and vehicle  
lk  
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;  
System overview - refrigerant circuit .  
♦ The sender for refrigerant pressure and refrigerant tempera‐  
ture is installed e.g. in place of the high pressure sender or  
pressure sender for refrigerant circuit ⇒ Heating, air condi‐  
tioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific work‐  
shop manual)  
♦ The sender for refrigerant pressure and refrigerant tempera‐  
ture, the pressure sender for refrigerant circuit and high pres‐  
sure sender come in different versions. Depending on the  
version, they can currently only be distinguished externally by  
the part number, which is why attention should be paid during  
renewal to their correct allocation (part number ⇒ Electronic  
parts catalogue ). Reason: These senders emit different sig‐  
nals, and the relevant control units can only evaluate the signal  
to which they have been matched ⇒ Vehicle diagnostic tester  
in “Guided Fault Finding” mode - air conditioning system and  
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit  
(vehicle-specific workshop manual).  
♦ The sender for refrigerant pressure and refrigerant tempera‐  
ture (and the pressure sender for refrigerant circuit) exchange  
information with the respective control unit via the data bus  
(e.g. “LIN bus”) when voltage is applied. The respective control  
units use this information to calculate the pressure and tem‐  
perature in the refrigerant circuit. Any faults detected in this  
way are passed on to the control unit ⇒ Vehicle diagnostic  
tester in “Guided Fault Finding” mode.  
♦ The sender for refrigerant pressure and refrigerant tempera‐  
ture transmits the measured valve for the pressure in the  
refrigerant circuit and the measured temperature to the con‐  
nected control unit. The pressure sender for refrigerant circuit  
only transmits the measured value for the pressure in the re‐  
frigerant circuit to the connected control unit. Even though on  
most vehicles only the pressure signal is evaluated, no other  
pressure sender may be installed in a vehicle for which provi‐  
sion is made for a refrigerant pressure and refrigerant tem‐  
perature sender ⇒ Electronic parts catalogue .  
1. Refrigerant circuit  
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♦ The temperature measured by this refrigerant pressure and  
lk  
temperature sender deviates from the actual temperature of  
the refrigerant in the refrigerant circuit owing to the design of  
the sender and the fitting location. It is therefore not evaluated  
at present by all control units and is used to regulate the air  
conditioning system ⇒ Heating, air conditioning; Rep. gr. 87 ;  
Refrigerant circuit; System overview - refrigerant circuit (vehi‐  
cle-specific workshop manual).  
♦ With this information, the respective control units calculate the  
pressure in the refrigerant circuit and actuate the downstream  
control units (radiator fan control unit, engine control unit etc.)  
via data bus. These control units subsequently actuate e.g. the  
air conditioning system magnetic clutch - N25- , the radiator  
fan and the engine ⇒ Vehicle diagnostic tester in “Guided Fault  
Finding” mode - air conditioning system and ⇒ Heating, air  
conditioning; Rep. gr. 87 ; Refrigerant circuit (vehicle-specific  
workshop manual).  
Senders for connection to a refrigerant circuit without valve  
Note  
These senders come in different versions, with different func‐  
tions and different designations. The sender for refrigerant  
pressure and refrigerant temperature shown as follows is in‐  
stalled e.g. in the Audi Q7 e-tron ⇒ Heating, air conditioning;  
Rep. gr. 87 ; Refrigerant circuit; System overview - refrigerant  
circuit .  
Different designations depending on the function and vehicle  
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;  
System overview - refrigerant circuit .  
Possible designations for these senders  
♦ Refrigerant pressure and temperature sender - G395- (e.g. in  
e-Golf, Audi Q7 e-tron)  
♦ Refrigerant pressure and temperature sender 2 - G826- (e.g.  
in Audi Q7 e-tron)  
♦ Refrigerant pressure and temperature sender 3 - G827- (e.g.  
in Audi Q7 e-tron)  
These senders -A- come in different versions that, depending on  
the version, can currently only be distinguished externally by the  
part number or, if the part number is the same, by the designation  
label -B-, which is why when renewing them it is important to en‐  
sure the correct allocation. Part number and designation ⇒  
Electronic parts catalogue and ⇒ Heating, air conditioning; Rep.  
gr. 87 ; Refrigerant circuit; System overview - Refrigerant circuit .  
When a voltage is applied, these senders exchange information  
with the respective control unit via the data bus (e.g. via “LIN  
bus”). The respective control units use this information to calcu‐  
late the pressure and temperature in the refrigerant circuit. Any  
faults detected in this way are passed on to the control unit ⇒ Ve‐  
hicle diagnostic tester in “Guided Fault Finding” mode.  
With this information, the respective control unit calculates the  
pressure in the refrigerant circuit and actuates the downstream  
control units or components (radiator fan control unit, pumps,  
valves etc.) via data bus according to the specifications ⇒ Vehicle  
diagnostic tester in “Guided Fault Finding” mode and ⇒ Heating,  
air conditioning; Rep. gr. 87 ; Refrigerant circuit; System overview  
- refrigerant circuit (vehicle-specific workshop manual).  
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1.2.23  
Air conditioner compressor regulating  
valve - N280-  
Note  
Refer to vehicle-specific refrigerant circuit for switching pres‐  
sures, removing and installing switches and location/design of  
switches ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant  
circuit; System overview - refrigerant circuit .  
♦ The regulating valve is fitted to the air conditioner compressor.  
It is actuated, for example, by the air conditioning system con‐  
trol unit - J301- , the operating and display unit for front air  
conditioning system - E87- or the Climatronic control unit -  
J255- (potentially also via data bus and an additional control  
unit depending on the vehicle) ⇒ Vehicle diagnostic tester in  
“Guided Fault Finding” mode - air conditioning system and ⇒  
lk  
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (ve‐  
hicle-specific workshop manual).  
♦ The regulating valve influences the pressure on the low pres‐  
sure side and thus the temperature at the evaporator.  
Note  
The air conditioner compressor regulating valve - N280- is an in‐  
tegral part of the air conditioner compressor and cannot be re‐  
newed individually on all air conditioner compressors ⇒  
Electronic parts catalogue .  
1.2.24  
Refrigerant temperature sender  
Note  
A refrigerant temperature sender (a temperature sender that  
does not evaluate the pressures) is currently not used by  
Volkswagen/Audi.  
Switching pressures, removing and installing switches and  
switch layout and design ⇒ Vehicle diagnostic tester in “Gui‐  
ded Fault Finding” mode - air conditioning system and ⇒  
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit (ve‐  
hicle-specific workshop manual).  
1. Refrigerant circuit  
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♦ The refrigerant temperature sender (with temperature-de‐  
pendent resistor) is installed e.g. in the high pressure line in  
the vicinity of the air conditioner compressor.  
♦ There is a direct correlation between temperature and pres‐  
sure in the refrigerant circuit: if there is too little refrigerant in  
the refrigerant circuit, the temperature in the refrigerant circuit  
rises during operation of the air conditioning system on the  
high pressure side greater than permitted for this pressure.  
Note  
The respective control unit, e.g. the operating and display unit for  
lk  
front air conditioning system - E87- or the Climatronic control unit  
- J255- evaluates the pressure and the temperature in the refrig‐  
erant circuit and switches off the air conditioner compressor if the  
temperature increases above the value stored for this pressure  
⇒ Vehicle diagnostic tester in “Guided Fault Finding” mode - air  
conditioning system and ⇒ Heating, air conditioning; Rep. gr.  
87 ; Refrigerant circuit (vehicle-specific workshop manual).  
1.3  
Possible complaints  
⇒ “1.3.1 Prerequisites for investigating a complaint”, page 64  
⇒ “1.3.2 Possible complaints”, page 64  
⇒ “1.3.3 Odours from heater and air conditioner unit”, page 66  
1.3.1  
Prerequisites for investigating a com‐  
plaint  
No fault was evident during fault finding in the electrical sys‐  
tem, vacuum system and air ducts/channels ⇒ Vehicle diag‐  
nostic tester in “Guided Fault Finding” mode - air conditioning  
system (and battery control), ⇒ Current flow diagrams, Elec‐  
trical fault finding and Fitting locations and ⇒ Heating, air  
conditioning; Rep. gr. 00 ; Repair instructions; Checking cool‐  
ing output .  
Self-diagnosis in “Guided Fault Finding” mode - air condition‐  
ing system (e.g. using ⇒ Vehicle diagnostic tester in “Guided  
Fault Finding” mode - air conditioning system) provides no  
evidence of a complaint.  
No shut-off condition for the air conditioner compressor is dis‐  
played in the measured values of the control unit of the air  
conditioning system ⇒ Vehicle diagnostic tester in “Guided  
Fault Finding” mode - air conditioning system.  
1.3.2  
Possible complaints  
Note  
For all complaints marked with *  
⇒ “2.14 Checking pressures”, page 170 .  
If on vehicles with 2 evaporators a problem is encountered in  
just one evaporator, check the pressures in the refrigerant cir‐  
cuit as well ⇒ “2.14 Checking pressures”, page 170 .  
♦ The cooling has failed completely.*  
♦ Insufficient cooling output at all vehicle speeds and engine  
speeds.*  
♦ No or insufficient cooling after driving a few miles. *  
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♦ No cooling or insufficient cooling from one or two evaporators  
(on vehicles with 2nd heater and air conditioner/evaporators).  
*
♦ Actuation of the air conditioner compressor (via the air condi‐  
tioning system magnetic clutch - N25- or the air conditioner  
compressor regulating valve - N280- ) is switched off by the  
respective control unit (e.g. the operating and display unit for  
front air conditioning system - E87- , the air conditioning sys‐  
tem control unit - J301- or the Climatronic control unit - J255- )  
due to pressure in the refrigerant circuit being too high or too  
low * ⇒ Vehicle diagnostic tester in “Guided Fault Finding”  
mode - air conditioning system.  
♦ The electrical air conditioner compressor - V470- is not actu‐  
ated by the control unit for air conditioning compressor - J842-  
due to pressure being too high or too low * ⇒ Vehicle diagnostic  
tester in “Guided Fault Finding” mode - air conditioning system  
and battery regulation.  
♦ If fresh air supply is lacking or drops significantly after a few  
miles (evaporator iced up) *⇒ Vehicle diagnostic tester in “Gui‐  
ded Fault Finding” mode - air conditioning system.  
In addition, the following problems may occur:  
lk  
The air conditioner compressor is noisy.  
– Re-tighten the securing bolts for the air conditioner compres‐  
sor and the air conditioner compressor bracket using a torque  
wrench ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant  
circuit; System overview - refrigerant circuit .  
– Check the routing of the refrigerant lines. These must not rest  
against other components and must not be under any strain  
(realign them if necessary) ⇒ Heating, air conditioning; Rep.  
gr. 87 ; Refrigerant circuit; System overview - refrigerant cir‐  
cuit .  
Noises (refrigerant hammering) occur immediately after the air  
conditioning is switched on and/or in a curve or when the brakes  
are applied:  
– Drain the refrigerant circuit, evacuate it and recharge (too  
much refrigerant or refrigerant oil in the circuit) ⇒ page 129  
and ⇒ “2.14 Checking pressures”, page 170 .  
Note  
Excess refrigerant oil in the circuit may also cause this problem  
(e.g. if the refrigerant oil level was not checked after the air con‐  
ditioner compressor was renewed) ⇒ page 79 .  
Water sprays out of the vents (in dash panel or footwell) although  
air conditioning system is otherwise functioning properly:  
– Check condensation drain to ensure that it is routed correctly.  
It should not be kinked or crushed ⇒ Heating, air conditioning;  
Rep. gr. 87 ; Front heater and air conditioner .  
– The condensed water drain valve must not be hindered in its  
operation by wax or underbody sealant and must open and  
close properly ⇒ Heating, air conditioning; Rep. gr. 87 ; Front  
heater and air conditioner .  
– Check plenum chamber cover. It must not be damaged and  
must be installed correctly (no water should run into the evap‐  
orator) ⇒ Heating, air conditioning; Rep. gr. 87 ; Overview of  
fitting locations - air conditioning system; Overview of fitting  
locations - components outside passenger compartment .  
1. Refrigerant circuit  
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– Check water drainage points of plenum chamber. These  
should not be blocked (e.g. by leaves) ⇒ Heating, air condi‐  
tioning; Rep. gr. 87 ; Overview of fitting locations - air condi‐  
tioning system; Overview of fitting locations - components  
outside passenger compartment .  
Note  
Installation location and other information about these compo‐  
nents ⇒ Heating, air conditioning; Rep. gr. 87 ; Overview of fitting  
locations - air conditioning system .  
lk  
1.3.3  
Odours from heater and air conditioner  
unit  
⇒ page 66  
⇒ page 67  
⇒ page 67  
Does the odour emanate from the evaporator or heat exchanger?  
♦ Fishy smell  
– Due to leak in engine's cooling system or in heat exchanger of  
heater and air conditioner unit.  
Note  
If the fishy smell is weaker when the temperature is set too “cold”  
or stronger when the temperature is set to “warm”, check the heat  
exchanger for leaks.  
♦ Smell of a burnt clutch  
♦ Vapours from foot mats, retrospectively installed seat covers  
etc.  
♦ Putrid, mouldy smell  
– Caused by accumulation of debris, pine needles etc. in plenum  
chamber  
Note  
Clean the plenum chamber.  
– Stagnant water that cannot flow out of plenum chamber.  
Note  
Check the water drainage points in the plenum chamber.  
♦ Smell from heater and air conditioner unit  
Note  
Smells that originate from the heater and air conditioner unit can  
be detected in fresh air mode and in recirculation mode.  
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– Due to too much condensate in the heater and air conditioner  
unit  
Note  
Check the condensation drain.  
– Due to an old or very dirty dust and pollen filter  
Note  
Check the dust and pollen filter.  
– Due to deposits on the fins of the evaporator  
Note  
Clean the evaporator with the ultrasonic air conditioner cleaning  
unit ⇒ page 67 or suction feed spray-gun and corresponding  
spray lance ⇒ page 67 .  
Ultrasonic air conditioner cleaning unit  
– The ultrasonic air conditioner cleaning unit must be placed in  
the front-passenger footwell and sprays the agent Aero-Clean.  
Aero-Clean neutralises microbes and bacteria in the heater  
and air conditioner unit.  
The device is provided with instructions for use.  
Current equipment ⇒ Electronic parts catalogue .  
Spraying the evaporator with the suction feed spray-gun and  
spray lance  
Directly spray the evaporator with cleaning solution using a spray  
lance (approx. 10 bar). The cleaning solution neutralises mi‐  
crobes and bacteria directly on the evaporator.  
To enable access to the evaporator, preparatory measures and  
different spray lances are required.  
Vehicle-specific operating instructions are provided with the  
evaporator cleaning solution ⇒ Electronic parts catalogue .  
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1.4  
Investigating leaks  
⇒ “1.4.1 General information about investigating leaks in the re‐  
frigerant circuit”, page 68  
⇒ “1.4.2 Searching for leaks in refrigerant circuits using an elec‐  
tronic leak detector”, page 69  
⇒ “1.4.3 Searching for leaks with UV leak detection system”, page  
71  
⇒ “1.4.4 Detecting leaks in a vacuum test using air conditioner  
service station , or in a pressure test”, page 77  
⇒ “1.4.5 Detecting leaks in a pressure test (with nitrogen or com‐  
pressed air)”, page 77  
1.4.1  
General information about investigating  
leaks in the refrigerant circuit  
Note  
Small leaks can be detected with e.g. an electronic leak de‐  
tector or a UV leak detector lamp.  
This workshop manual describes 2 ways of tracing leaks in  
refrigerant circuits. These procedures have been tested and  
lead to a reliable result under the different usage conditions if  
they are performed correctly and in accordance with the spe‐  
cific complaint.  
Various methods are offered in the open market with which  
leaks in refrigerant circuits can be traced. These methods are  
not able to provide clear results in all cases and, unless the  
exact procedure is adhered to, they can also result in various  
components of the refrigerant circuit being identified as having  
leaks even though they do not. Furthermore, certain process‐  
es can cause preliminary or permanent damage to the com‐  
ponents of the refrigerant circuit  
♦ Components that are found to be leaking must not be repaired.  
They must be renewed instead.  
♦ A leaking refrigerant circuit must not be charged with refriger‐  
ant. Therefore, evacuate an empty refrigerant circuit and  
check for leaks before charging the system with refrigerant  
⇒ “2.5 Evacuating refrigerant circuit”, page 140 .  
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Note  
VW/Volkswagen/Audi does not endorse the use of chemical  
substances (leak inhibitor additives) for purposes of sealing  
leaks in refrigerant circuits.  
Chemical substances used to seal leaks form deposits in the  
refrigerant circuit. These can impair the function of the air con‐  
ditioning system and cause the air conditioning system (and  
your air conditioner service station ) to fail.  
lk  
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 (not even by cleaning/flush‐  
ing). The refrigerant circuit can only be repaired by replacing  
all components that have come into contact with this sub‐  
stance.  
1.4.2  
Searching for leaks in refrigerant circuits  
using an electronic leak detector  
Special tools and workshop equipment required  
♦ Electronic leak detector or proprietary device  
Note  
Leaks in R1234yf refrigerant circuits can only be found using  
electronic leak detection devices designed for R1234yf refrig‐  
erant.  
The various refrigerants have a different molecular structure.  
The sensors of electronic leak detection devices are adapted  
to these molecules. If an electronic leak detection device is  
used that is not designed for R1234yf refrigerant, it will not  
respond to R1234yf refrigerant at all or only in larger concen‐  
trations in the vicinity of the leak. For this reason, electronic  
leak detection devices designed only for R134a refrigerant  
cannot be used for leak detection in the R1234yf refrigerant  
circuit.  
Depending on the type of heater and air conditioner unit, a leak  
from the evaporator can be investigated by holding the test  
probe of the leak detector against the glove compartment  
cooler connection in the heater and air conditioner unit, or by  
holding the test probe against the open condensation drain  
connection of the heater and air conditioner unit with the con‐  
densation drain hose pulled off.  
Performing leak detection on a completely empty refrigerant cir‐  
cuit caused by a leak:  
Note  
With a completely empty refrigerant circuit, proceed as follows to  
ensure that no more refrigerant than necessary enters the envi‐  
ronment during testing:  
– Evacuate refrigerant circuit using air conditioner service sta‐  
tion ⇒ “2.5 Evacuating refrigerant circuit”, page 140 .  
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Note  
If a larger leak is detected during the evacuation process, de‐  
termine the cause and rectify as described  
⇒ “2.5 Evacuating refrigerant circuit”, page 140 .  
If during the evacuation process no leak is detected or a very  
small leak is detected that cannot be located using the vacuum  
test, proceed as follows.  
– If the refrigerant circuit is completely empty, charge the system  
with approx. 10% of refrigerant and perform leak detection in  
the same way as per a fully charged refrigerant circuit  
⇒ page 70 .  
Performing leak detection on a charged refrigerant circuit:  
– Switch off ignition.  
– Start the leak detector according to the operating instructions.  
lk  
– Always hold probe tip under location of suspected leak.  
If, inherent of the design, the rate of clicks rises or a wailing noise  
is heard, a leak has been detected ⇒ operating instructions for  
leak detector .  
Note  
Refrigerant gas is quickly dispersed by movement of air.  
Draughts must therefore be avoided during leak detection.  
Refrigerant gas is heavier than air and therefore sinks at the  
point at which it escapes.  
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1.4.3  
Searching for leaks with UV leak detec‐  
tion system  
Note  
Certain leaks are difficult or impossible to find using an elec‐  
tronic leak detection device. To investigate these leaks, leak  
detection can be performed using the leak detection system  
⇒ Electronic parts catalogue .  
Refrigerant and refrigerant oil leaks out of the refrigerant circuit  
when the circuit has a leak. This oil generally remains in the  
vicinity of the leak location. To make the oil visible underlUk V  
light, a small amount of fluorescent fluid must be added to the  
refrigerant circuit. This fluid (PAG oil with an additive which  
lights up under UV light) is injected into the refrigerant circuit  
and distributed with the refrigerant oil when the air conditioning  
system is switched on.  
The air conditioning system must be operated for at least  
60 minutes to ensure that the injected leak detecting additive  
is distributed throughout the entire refrigerant circuit (air con‐  
ditioner compressor must run). The leak may become visible  
under UV light after a short period, but this depends on the  
size of the leak.  
The refrigerant oil with additive, which lights up under UV light,  
can be added directly in an open circuit or charged after emp‐  
tying the circuit with air conditioner service station via the  
service connection.  
If the leak detection additive is added to the refrigerant circuit  
via the service connection, a small amount of leak detection  
additive will be deposited in the service connection. Carefully  
remove any deposits so that this area is not mistaken for a leak  
during subsequent leak detection.  
If a component from a circuit in which leak detection additive  
is filled is renewed, thoroughly clean the connection points to  
other components after assembling the refrigerant circuit. Dur‐  
ing subsequent leak detection, deposits of leak detection ad‐  
ditive could otherwise be mistaken for leaks at the connecting  
point.  
When purging the refrigerant circuit, refrigerant oil and there‐  
fore also leak detection additive also enter the air conditioner  
service station . The refrigerant oil is separated from the re‐  
frigerant in the oil separator of the air conditioner service  
station and removed from the air conditioner service station  
via the drainage outlet. The drained refrigerant oil may not be  
reused. It must be replaced with fresh refrigerant oil.  
If leak detection fluid was injected during a previous repair of  
the refrigerant circuit, observe the following: do not inject new  
leak detection fluid unless the refrigerant machine oil has been  
replaced. If only some of the refrigerant machine oil was re‐  
placed then only the respective amount of leak detection fluid  
should be injected. If, for example, 100 ml of refrigerant oil is  
replaced in a vehicle with 250 ml of refrigerant oil, inject only  
1 ml (cm3) of leak detection additive.  
Certain materials and their compounds (e.g. oxidisation prod‐  
ucts on components made from aluminium, corrosion protec‐  
tion wax, etc.) also light up under UV light.  
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Depending on the type of air conditioner service station , it can  
also be used to add the leak detection additive directly into the  
system. See the operating instructions of your air conditioner  
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service station ⇒ Operating instructions air conditioner service  
station .  
Leak detection on an empty, leaking refrigerant circuit  
– With a completely empty refrigerant circuit, proceed as follows  
to ensure that no more refrigerant than necessary enters the  
environment during testing:  
– Evacuate refrigerant circuit with air conditioner service station  
⇒ “2.5 Evacuating refrigerant circuit”, page 140 .  
Note  
If a larger leak is detected during the evacuation process, deter‐  
mine the cause and rectify as described  
⇒ “1.4.4 Detecting leaks in a vacuum test using air conditioner  
service station , or in a pressure test”, page 77 and  
⇒ “2.5 Evacuating refrigerant circuit”, page 140 .  
If during the evacuation process no leak is detected or a very  
small leak is detected that cannot be located during evacuation,  
proceed as follows.  
Note  
Only use UV leak detection additive approved for R1234yf re‐  
frigerant.  
The leak detection additive contains refrigerant oil for the most  
part. Since special refrigerant oils are required for R1234yf  
refrigerant, only UV leak detection additives may be used that  
use this oil as a carrier. UV leak detection additives developed  
for R134a refrigerant are therefore unsuitable.  
For refrigerant circuits with R1234yf and R134a refrigerant,  
different refrigerant oils (PAG oils) are used, which is why it is  
important to ensure correct allocation of the leak detection ad‐  
ditive (PAG oil with an additive that lights up under UV light).  
Charge the refrigerant circuit with UV leak detection additive  
using the air conditioner service station ⇒ page 75 .  
Charge the refrigerant circuit with UV leak detection additive  
using the leak detection system ⇒ page 75 .  
– Charge the refrigerant circuit with the specified amount of UV  
leak detection additive and the requisite amount of refrigerant  
⇒ page 72 , ⇒ “2.6 Charging refrigerant circuit”, page 146  
and ⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data .  
– Run the air conditioning system for at least 60 minutes with  
the air conditioner compressor switched on.  
– Investigate leaks with UV leak detection system  
⇒ page 75 .  
Charge the refrigerant circuit with UV leak detection additive using  
the air conditioner service station .  
– Charge the refrigerant circuit with UV leak detection additive  
and the requisite amount of refrigerant using air conditioner  
service station ⇒ “2.6 Charging refrigerant circuit”, page 146  
and ⇒ Heating, air conditioning; Rep. gr. 00 ; Technical data .  
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Note  
The amount of UV leak detection additive to be charged in the  
refrigerant circuit with a refrigerant oil volume up to 150 cm3  
is 3.0 ± 0.5 ml. If the volume of refrigerant oil in the refrigerant  
circuit is greater, more UV leak detection additive must be  
added accordingly, e.g. 5.0 ± 0.5 ml in a refrigerant circuit with  
a refrigerant oil volume of 250 cm3. If the UV leak detection  
additive is filled with an air conditioner service station , the  
volume to be set in your air conditioner service station may  
differ. Therefore, observe the relevant operating instructions  
⇒ Operating instructions Air conditioner service station .  
For the specific volume of refrigerant oil in the refrigerant cir‐  
cuit, refer to the vehicle-specific workshop manual ⇒ Heating,  
air conditioning; Rep. gr. 00 ; Technical data .  
If leak UV leak detection additive was injected during a previ‐  
ous repair of the refrigerant circuit, observe the following: do  
not inject new UV leak detection additive unless the refrigerant  
machine oil has been replaced. If only some of the refrigerant  
machine oil was replaced then only the respective amount of  
UV leak detection additive should be injected. If, for example,  
50 ml of refrigerant oil is replaced in a vehicle with 150 ml of  
refrigerant oil, inject only 1.0 ml (cm3) of UV leak detection  
additive.  
The leak detection system comprises the following parts:  
♦ Cleaning agent -3-  
♦ UV leak detection lamp -4-  
♦ UV absorbing eye protection -5-  
lk  
♦ Sticker -6-  
♦ Gloves -8-  
Note  
Items -1-, -2- and -7- in the diagram can be disregarded.  
Special tools and workshop equipment required  
♦ Leak detecting system  
♦ Air conditioner service station with means of adding UV leak  
detection additive in the refrigerant circuit ⇒ Electronic parts  
catalogue .  
♦ Approved leak detection additive ⇒ Electronic parts cata‐  
logue .  
– Evacuate the refrigerant circuit as per the instructions, and  
charge the system with UV leak detection additive and refrig‐  
erant ⇒ “2.5 Evacuating refrigerant circuit”, page 140 and  
⇒ “2.6 Charging refrigerant circuit”, page 146 .  
– Wait until the pressures on the high pressure and low pressure  
side have settled.  
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– Detach the air conditioner service station from the refrigerant  
circuit and switch off  
⇒ “2.8 Switching off air conditioner service station and sepa‐  
rating from refrigerant circuit”, page 151 .  
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– Attach a label close to the service connections that shows that  
the refrigerant circuit has been injected with a UV leak detec‐  
tion additive.  
– Remove any remains of UV leak detection additive from the  
service connection e.g. with absorbent paper, and clean the  
area with cleaning agent - VAS 6201/3- .  
– Seal the service connection with a cap.  
– Bring the air conditioning system into operation.  
– Run the air conditioning system for at least 60 minutes with  
the air conditioner compressor switched on.  
– Search for leaks in the refrigerant circuit using a UV lamp  
⇒ page 75 .  
Searching for leaks in refrigerant circuit using a UV lamp  
CAUTION  
Risk of eyes being dazzled by UV light.  
– Wear protective goggles.  
– Never glare into the UV lamp.  
– Never point a UV lamp at another person.  
– On vehicles with high-voltage system, switch off “stationary air  
lk  
conditioning” function (deactivate)⇒ Owner's Manual and ⇒  
Operating instructions of infotainment/MMI .  
– Switch off ignition.  
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Note  
The air conditioning system must be operated for at least  
60 minutes to ensure that the injected leak detecting additive  
is distributed throughout the entire refrigerant circuit (air con‐  
ditioner compressor must run). The leak may become visible  
under UV light after a short period, but this depends on the  
size of the leak.  
Depending on the size and location of the leak, it can take  
several days until sufficient refrigerant oil with UV leak detec‐  
tion additive has leaked out and the leak can be easily identi‐  
fied as such.  
In the event of leaks at the evaporator, the additive may be  
washed out with the condensate and emerge via the conden‐  
sate drain. As the evaporator is not accessible on the majority  
of models without a great amount of work, a check of the con‐  
densed water drain point can indicate a leaking evaporator.  
This does however require the additive to have been in the  
refrigerant circuit for a lengthy period (several days).  
The protective eye wear is not only required to protect the  
eyes. It also amplifies the illumination of the UV leak detection  
additive under the UV lamp.  
Depending on how easy it is to reach various components in  
the refrigerant circuit, it may be necessary to remove certain  
parts from the vehicle (e.g. bumper or air filter).  
Only a small amount of refrigerant oil reaches certain areas of  
the refrigerant circuit during operation of the air conditioning  
system (e.g. a cap fitted at the top of a receiver installed on  
the condenser). If there is a leak in these areas, it may take  
quite some time before a sufficient quantity of refrigerant with  
refrigerant oil and additive escapes at this point and can be lit  
up under UV light showing where the leak is. At these points,  
therefore, it may be more pertinent to search for a leak using  
an electronic leak detection device  
⇒ “1.4.2 Searching for leaks in refrigerant circuits using an  
electronic leak detector”, page 69 .  
– Position the vehicle in a darker area of the workshop (in day‐  
light or under strong lighting the effect of the UV lamp is greatly  
reduced).  
– Check accessibility to various components of the refrigerant  
circuit and remove parts in the vicinity of the refrigerant circuit  
that obstruct the view of the refrigerant circuit components  
(e.g. noise insulation and bumper).  
– Protect eyes with safety goggles.  
– Connect UV lamp to a 12 V battery (vehicle battery). Ensure  
that the polarity of the connections is correct.  
– Switch on the UV lamp and light up the components in the  
refrigerant circuit. Positions at which refrigerant - along with  
refrigerant oil and leak detection additive - can leak out fluo‐  
resce (light-up) under UV light.  
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1.4.4  
Detecting leaks in a vacuum test using  
air conditioner service station , or in a  
pressure test  
All vehicles  
CAUTION  
Risk of freezing injury caused by escaping pressurised refrig‐  
lk  
erant.  
There is a risk of injury to the skin and parts of the body due to  
freezing.  
– Wear protective gloves.  
– Wear protective goggles.  
– Extract refrigerant and open the refrigerant circuit immedi‐  
ately afterwards.  
– If more than 10 minutes have passed since the refrigerant  
was extracted, repeat the extraction process before opening  
the refrigerant circuit. Pressure could build up in the refrig‐  
erant circuit from continued evaporation.  
– Switch off ignition.  
♦ Detecting leaks in a vacuum test using air conditioner service  
station , or in a pressure test  
⇒ “2.5 Evacuating refrigerant circuit”, page 140  
Note  
Smaller leaks in the refrigerant circuit (less than 100 g refrig‐  
erant loss per year) cannot usually be found by means of the  
vacuum test or pressure test. The amount of air entering the  
system or the nitrogen-air escaping it is too low to detect the  
faulty area through noise.  
It is also not always possible to detect leaks in the refrigerant  
circuit with more than 100 g refrigerant loss per year by means  
of the vacuum test or pressure test, depending on the envi‐  
ronmental conditions (noise around the area, location of leak,  
etc.). The air entering the system and nitrogen escaping it  
could be too low to generate a noise that would be noticeable  
in the faulty area.  
Larger leaks in the refrigerant circuit (e.g. more than 100 g  
refrigerant loss per day caused by a stone hitting the con‐  
denser) can be detected depending on the environmental  
conditions, e.g. noise coming from the faulty area, which is  
noticeable during the vacuum test or pressure test  
⇒ “2.5 Evacuating refrigerant circuit”, page 140 .  
– Perform vacuum or pressure test ⇒ page 143 .  
1.4.5  
Detecting leaks in a pressure test (with  
nitrogen or compressed air)  
♦ Perform a vacuum test using the air conditioner service station  
to see if any leaks can be found  
⇒ “2.5 Evacuating refrigerant circuit”, page 140 . If a leak can  
be detected but not the exact location of the leak, an additional  
pressure test can be performed using nitrogen or compressed  
air ⇒ page 143  
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Note  
Smaller leaks in the refrigerant circuit (less than 100 g refrig‐  
erant loss per year) cannot usually be found by means of the  
vacuum test or pressure test. The amount of air entering the  
system or the nitrogen-air escaping it is too low to detect the  
faulty area through noise.  
It is also not always possible to detect leaks in the refrigerant  
circuit with more than 100 g refrigerant loss per year by means  
of the vacuum test or pressure test, depending on the envi‐  
ronmental conditions (noise around the area, location of leak,  
etc.). The air entering the system and nitrogen escaping it  
could be too low to generate a noise that would be noticeable  
in the faulty area.  
Larger leaks in the refrigerant circuit (e.g. more than 100 g  
refrigerant loss per day caused by a stone hitting the con‐  
lk  
denser) can be detected depending on the environmental  
conditions, e.g. noise coming from the faulty area, which is  
noticeable during the vacuum test or pressure test  
⇒ “2.5 Evacuating refrigerant circuit”, page 140 .  
A larger leak in the refrigerant circuit can be detected, for ex‐  
ample, by pressurising the circuit to a maximum of 15 bar using  
cleaned and dried compressed air or nitrogen ⇒ page 124 . If  
the leak is large enough, the leakage point can be detected by  
sound as the gas escapes.  
Tools required:  
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♦ Quick-release coupling adapter -A- (you can also unscrew the  
lk  
adapter from your air conditioner service station and use it for  
this test).  
♦ Charge hose -A- (e.g. with a M12 x 1.5-6G thread, SAE J639  
standard), depending on the thread of the quick-release cou‐  
pling adapter (cut off), with a suitable adapter -B- (for connec‐  
tion to the compressed air system used in your workshop or  
to a pressure reducer for nitrogen)  
♦ Combination fine filter element for compressed air system with  
an oil, dirt and water separator (to ensure that the refrigerant  
circuit is pressurised with compressed air that is clean, dry and  
free of oil) for the leakage test with compressed air  
♦ Manifold gauge with pressure reducer for nitrogen (maximum  
reduced pressure: 15 bar) -1-, a full nitrogen gas cylinder -3-  
and a charge hose -2- (e.g. with M12 x 1.5-6G thread in  
accordance with SAE J639, to which a quick-release coupling  
adapter for service connection is fitted) for leakage test with  
nitrogen  
– Perform pressure test ⇒ page 143 .  
1.5  
Renewing components  
⇒ “1.5.1 General information about renewing components”, page  
79  
⇒ “1.5.2 Renewing leaking or damaged components of empty re‐  
frigerant circuit (apart from air conditioner compressor and re‐  
ceiver)”, page 81  
⇒ “1.5.3 Renewing leaking or damaged components of charged  
refrigerant circuit (apart from air conditioner compressor and re‐  
ceiver)”, page 84  
⇒ “1.5.4 Renewing air conditioner compressor with no need to  
clean refrigerant circuit”, page 85 .  
⇒ “1.5.5 Renewing air conditioner compressor due to leaks or in‐  
ternal damage”, page 87  
⇒ “1.5.6 Renewing desiccant cartridge / receiver after cleaning  
refrigerant circuit”, page 88  
⇒ “1.5.7 Renewing receiver with no need to clean refrigerant cir‐  
cuit”, page 90 .  
⇒ “1.5.8 Renewing desiccant cartridge / desiccant bag with no  
need to clean refrigerant circuit”, page 91  
1.5.1  
General information about renewing  
components  
The receiver or desiccant cartridge need not be renewed under  
the following circumstances:  
♦ The opened refrigerant circuit is sealed immediately with clean  
plugs, e.g. from the engine bung set - VAS 6122- .  
♦ After an accident in which there was no damage to the receiv‐  
er.  
♦ Repairs are performed quickly (not for longer than the normal  
repair time).  
♦ The vehicle is no more than 5 years old.  
1. Refrigerant circuit  
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The receiver or dryer cartridge should be renewed under the fol‐  
lowing circumstances:  
♦ The refrigerant circuit has been opened for an indeterminate  
period (seepage leak).  
♦ The receiver is damaged (e.g. in an accident).  
♦ Repairs are performed over a longer time than the normal re‐  
pair time.  
♦ The refrigerant circuit was opened and the vehicle is more than  
5 years old.  
♦ The refrigerant circuit has been blown through with nitrogen.  
♦ The refrigerant circuit has been flushed with R1234yf.  
♦ The air conditioner compressor seizes.  
All components of the refrigerant circuit that were submitted to  
quality monitoring must be sealed (use the original sealing  
caps from the replacement part).  
Renew damaged or leaky components of the refrigerant circuit  
⇒ page 79 .  
All components of the refrigerant circuit that were submitted to  
quality monitoring must be sealed (use the original sealing  
caps from the replacement part).  
The replacement air conditioner compressor, receiver, evap‐  
orator and condenser were previously charged with nitrogen.  
This filling is being gradually discontinued, or the pressure of  
the nitrogen filling is so low that escaping gas is no longer  
perceptible when the part is initially opened.  
Where vehicles are fitted with an air conditioner compressor  
without a magnetic clutch, the engine should be started only  
when the refrigerant circuit has been fully assembled (since  
lk  
the air conditioner compressor will always run when the engine  
is running) .  
The air conditioner compressor with air conditioner compres‐  
sor regulating valve - N280- (without air conditioning system  
magnetic clutch - N25- ) is switched to internal lubrication in  
the event of an empty refrigerant circuit, in which case only a  
small amount of oil is pumped from the air conditioner com‐  
pressor into the circuit.  
80  
Rep. gr.87 - Air conditioning system  
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Note  
The following replacement parts (air conditioner compressor,  
receiver, evaporator and condenser) could be filled with nitro‐  
gen gas, though this filling is not always guaranteed. There‐  
fore, little or no pressure equalisation may be perceived when  
the sealing plugs of the replacement part are unscrewed.  
Depending on the storage location and storage period, it is  
possible on components filled with nitrogen ex-works that  
barely any pressure equalisation - if at all - is perceptible and,  
as such, nothing can be said about the leak-tightness of the  
component. This means, for example, that the nitrogen gas  
filling could escape through the shaft seal of a replacement air  
conditioner compressor in the course of time, even though the  
air conditioner compressor is leak-tight.  
Since spare parts are sometimes stored for long periods in  
various places, there is a good chance that gas may escape  
from some parts when first opened but not from others (even  
of the same part number). Therefore, be careful when un‐  
screwing the sealing plugs from the replacement part connec‐  
tions and allow the nitrogen gas to escape slowly.  
One or 2 expansion valves and a receiver or desiccant con‐  
tainer are installed in the refrigerant circuit ⇒ Heating, air  
conditioning; Rep. gr. 87 ; Refrigerant circuit; System over‐  
view - refrigerant circuit .  
Renew the desiccant cartridge or components with desiccant  
bag (receiver) after cleaning the refrigerant circuit (flush with  
R1234yf refrigerant  
⇒ “1.6 Cleaning refrigerant circuit”, page 92 ). When doing  
so, keep the circuit closed for as long as possible to keep the  
ingress of moisture as low as possible.  
Seal open connections and pipes (to prevent absorption of  
moisture).  
lk  
Note  
Contaminated refrigerant oils are to be disposed of as used oil of  
unknown origin (observe local regulations) ⇒ VW / Audi Service‐  
Net .  
1.5.2  
Renewing leaking or damaged compo‐  
nents of empty refrigerant circuit (apart  
from air conditioner compressor and re‐  
ceiver)  
The refrigerant circuit was completely empty (e.g. larger leaks or  
ruptured hose line)  
♦ Observe the general information about renewing components  
⇒ “1.5.1 General information about renewing components”,  
page 79  
1. Refrigerant circuit  
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Note  
If there is just a small leak and the refrigerant only escaped in  
small quantities (e.g. small leakage point), the amount of re‐  
frigerant oil that escapes and the degree of moisture ingress  
are not enough to impair the function of the air conditioning  
system once the repair has been carried out.  
The measures marked with * should only be performed if leaks  
are more pronounced (e.g. following an accident).  
Electrical air conditioner compressor  
– Remove defective component * ⇒ Heating, air conditioning;  
Rep. gr. 87 ; Refrigerant circuit; System overview - refrigerant  
circuit .  
– Remove electrical air conditioning compressor and clean  
(flush with R1234yf refrigerant) *  
⇒ “1.6 Cleaning refrigerant circuit”, page 92 and ⇒ Heating,  
air conditioning; Rep. gr. 87 ; Air conditioner compressor; Re‐  
moving and installing electrical air conditioning compressor  
(vehicle-specific workshop manual).  
– Clean the refrigerant circuit (flush with R1234yf refrigerant)*  
⇒ “1.6 Cleaning refrigerant circuit”, page 92 .  
– Completely charge the air conditioner compressor or refriger‐  
ant circuit with the requisite amount of oil  
⇒ “1.5.4 Renewing air conditioner compressor with no need to  
clean refrigerant circuit”, page 85 and ⇒ Heating, air condi‐  
tioning; Rep. gr. 00 ; Technical data (approved refrigerant oils  
and fill capacities for refrigerant oil in vehicle-specific work‐  
shop manual).  
lk  
Mechanical air conditioner compressor  
– Remove defective component * ⇒ Heating, air conditioning;  
Rep. gr. 87 ; Refrigerant circuit; System overview - refrigerant  
circuit .  
– Remove air conditioner compressor.* ⇒ Heating, air condi‐  
tioning; Rep. gr. 87 ; Air conditioner compressor .  
82  
Rep. gr.87 - Air conditioning system  
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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
– Unscrew oil drain plug -B- / -D- from air conditioner compres‐  
sor -A-.*  
Note  
The design of the oil drain plug -B- / -D- and seal -C- / -E- may  
vary (depending on the manufacturer of the air conditioner  
compressor) ⇒ Heating, air conditioning; Rep. gr. 87 ; Air  
conditioner compressor (vehicle-specific workshop manual).  
When installing the oil drain plug -B-/-D-, observe the corre‐  
sponding torque specification (depending on the manufacturer  
of the air conditioner compressor and the design of the oil drain  
plug). Please note that the oil drain plug of air conditioner  
compressors manufactured by Denso and Delphi is equipped  
with an oil seal ⇒ Heating, Air conditioning; Rep. gr. 87 ; Air  
conditioning compressor, Assembly overview - drive unit of air  
conditioner compressor (currently valid specified torque:  
30 Nm for “Denso” and 15 Nm for “Delphi” air conditioner com‐  
pressor). The oil drain plug of air conditioner compressors  
manufactured by “Sanden” and “Zexel- / Valeo” may be equip‐  
ped with an O-ring or an oil seal (depending on the vehicle  
equipment; currently valid specified torque: 10 Nm, respec‐  
tively).  
On the Denso air conditioner compressor, for example, the oil  
drain plug -D- has an oil seal -E-; renew ⇒ Heating, air con‐  
ditioning; Rep. gr. 87 ; Air conditioner compressor (vehicle-  
specific workshop manual) and ⇒ Electronic parts catalogue .  
On the Sanden air conditioner compressor, for example, the  
oil drain plug -B- has a seal -C-; renew ⇒ Heating, air condi‐  
tioning; Rep. gr. 87 ; Air conditioner compressor (vehicle-  
specific workshop manual) and ⇒ Electronic parts catalogue .  
If a seal (oil seal or O-ring) fitted to the oil drain plug is not  
available as a replacement part, the removed old part can be  
reused (as an exception to the general rule of using new seals  
only). The old seal, however, must always be checked for  
damage prior to installation. If any damage or deformation is  
detected on the old seal, it must be renewed with a commer‐  
cially available new part.  
After filling the refrigerant circuit, check the installed oil drain  
plug for leaks using e.g. an electronic leak detector.  
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.  
– Pour out old refrigerant oil from the air conditioner compressor  
*
⇒ “1.5.4 Renewing air conditioner compressor with no need to  
clean refrigerant circuit”, page 85 (disposal ⇒ VW / Audi  
ServiceNet ).  
1. Refrigerant circuit  
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lk  
All vehicles  
Note  
Then pour new refrigerant oil in the air conditioner compressor  
in a volume that equates to the refrigerant oil in the replace‐  
ment compressor * ⇒ Heating, air conditioning; Rep. gr. 00 ;  
Technical data; refrigerant oil .  
Different refrigerant oil and volumes for different air condition‐  
er compressors ⇒ Heating, air conditioning; Rep. gr. 00 ;  
Technical data; refrigerant oil .  
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 the new reservoir or receiver  
or a refrigerant line ⇒ Heating, air conditioning; Rep. gr. 00 ;  
Technical data; refrigerant oil .  
If dirt enters the air conditioner compressor whilst the refrig‐  
erant circuit is open (e.g. after an accident), the air conditioner  
compressor is to be renewed ⇒ Heating, air conditioning; Rep.  
gr. 87 ; Air conditioner compressor .  
Clean the refrigerant circuit (flush with R1234yf refrigerant) *  
⇒ “1.6 Cleaning refrigerant circuit”, page 92 .  
– Renew desiccant cartridge and receiver ⇒ Heating, air con‐  
ditioning; Rep. gr. 87 ; Refrigerant circuit; System overview -  
refrigerant circuit .  
– Assemble the refrigerant circuit, evacuate and refill  
⇒ page 129 .  
1.5.3  
Renewing leaking or damaged compo‐  
nents of charged refrigerant circuit  
(apart from air conditioner compressor  
and receiver)  
There is still refrigerant in the refrigerant circuit (e.g. the leak is  
small)  
♦ Observe the general information about renewing components  
⇒ “1.5.1 General information about renewing components”,  
page 79  
– Drain refrigerant circuit ⇒ page 129 .  
– Remove the defective part, blow through with compressed air  
and collect any escaping refrigerant oil.  
3
The refrigerant oil that is blown out (plus 20 cm for the evap‐  
3
orator, plus 10 cm for the condenser, refrigerant lines and  
refrigerant hoses) should be poured into the new component  
as fresh refrigerant oil.  
Note  
Dispose of old refrigerant oil (observing local regulations) ⇒ VW /  
Audi ServiceNet .  
– Assemble the refrigerant circuit, evacuate and charge  
⇒ page 129 .  
84  
Rep. gr.87 - Air conditioning system  
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1.5.4  
Renewing air conditioner compressor  
with no need to clean refrigerant circuit  
Note  
Clean the refrigerant circuit. In other words, flush with R1234yf  
refrigerant ⇒ “1.6 Cleaning refrigerant circuit”, page 92 .  
♦ Observe the general information about renewing components  
⇒ “1.5.1 General information about renewing components”,  
page 79  
For example with external damage from an accident  
– Drain refrigerant circuit  
⇒ “1.6 Cleaning refrigerant circuit”, page 92 .  
– Remove air conditioner compressor ⇒ Heating, air condition‐  
ing; Rep. gr. 87 ; Air conditioner compressor .  
Electrical air conditioner compressor  
– Flush the defective electrical air conditioning compressor to  
remove the refrigerant oil (make a note of the volume of re‐  
frigerant oil flushed out)  
⇒ “2.11 Cleaning electrical air conditioning compressor”, page  
155 .  
lk  
Note  
If the volume of refrigerant oil flushed out of the defective air  
conditioner compressor is more than 75% of that in the re‐  
placement air conditioner compressor, do not flush the re‐  
placement air conditioner compressor (a residual amount  
always remains in the air conditioner compressor, which  
means that the amount of refrigerant oil in the refrigerant circuit  
is negligible).  
If less than 75% of the specified amount of refrigerant oil is  
flushed out of the defective air conditioner compressor, the  
remaining amount is still in the components of the refrigerant  
circuit. To prevent the system from being overfilled with refrig‐  
erant oil, the refrigerant circuit or the electrical air conditioning  
compressor is to be flushed.  
– Flush the refrigerant circuit or new electrical air conditioning  
compressor to remove the refrigerant oil  
⇒ “1.6 Cleaning refrigerant circuit”, page 92 and  
⇒ “2.11 Cleaning electrical air conditioning compressor”, page  
155 .  
– Dispose of refrigerant oil flushed out of defective and new air  
conditioner compressor / refrigerant circuit ⇒ VW / Audi Serv‐  
iceNet (observe local regulations).  
Note  
The design of the electrical air conditioning compressor is such  
that flushing is a requisite to remove the refrigerant oil (the refrig‐  
erant oil cannot be poured out as is the case with mechanical air  
conditioning compressors with oil drain plug)  
⇒ “1.5.2 Renewing leaking or damaged components of empty re‐  
frigerant circuit (apart from air conditioner compressor and re‐  
ceiver)”, page 81 .  
1. Refrigerant circuit  
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– Only fill the replacement air conditioner compressor with fresh  
refrigerant oil equivalent to volume of oil that was flushed out  
(from the defective air conditioner compressor).  
Note  
If for instance 70 cm3 refrigerant oil was poured out of the de‐  
fective air conditioner compressor, and 140 cm3 oil was pour‐  
ed out of the replacement air conditioner compressor (a small  
quantity of refrigerant oil remains in the air conditioner com‐  
pressor and potentially in the air conditioner service station ).  
lk  
The air conditioner compressor to be installed must be filled  
in this instance with 70 cm3 of refrigerant oil (the refrigerant oil  
flushed out of the replacement air conditioner compressor  
must not be used as it may have been contaminated in the air  
conditioner service station ).  
Different refrigerant oils and volumes for different air condi‐  
tioner compressors ⇒ Heating, air conditioning; Rep. gr. 00 ;  
Technical data .  
If quite a large amount of refrigerant oil was flushed out of the  
defective air conditioner compressor (more than approx.  
40 cm 3), the remaining refrigerant oil can also be poured in  
the evaporator, a refrigerant line or the reservoir/receiver/inner  
heat exchanger ⇒ Heating, air conditioning; Rep. gr. 87 ; Re‐  
frigerant circuit; System overview - refrigerant circuit , ⇒  
Heating, air conditioning; Rep. gr. 00 ; Technical data .  
Mechanical air conditioner compressor  
– Remove oil drain plug from air conditioner compressor ⇒  
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;  
System overview - refrigerant circuit .  
Note  
Different versions of oil drain plug and corresponding seal (either  
a seal or an O-ring may be installed, renew)  
⇒ “1.5.2 Renewing leaking or damaged components of empty re‐  
frigerant circuit (apart from air conditioner compressor and re‐  
ceiver)”, page 81 and ⇒ Electronic parts catalogue .  
– To speed up draining of the refrigerant oil, rotate the shaft of  
the air conditioner compressor using e.g. the magnetic clutch  
pulley.  
– Pour out old refrigerant oil from the air conditioner compressor  
and dispose ⇒ VW / Audi-ServiceNet (observe local regula‐  
tions).  
– Remove oil drain screw from replacement air conditioner com‐  
pressor, pour out refrigerant oil and replace it with only the  
quantity of fresh refrigerant oil equal to the amount of refrig‐  
erant oil poured out of the defective air conditioner compressor  
⇒ “1.5.2 Renewing leaking or damaged components of empty  
refrigerant circuit (apart from air conditioner compressor and  
receiver)”, page 81 .  
86  
Rep. gr.87 - Air conditioning system  
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Note  
If for instance 50 cm3 refrigerant oil was poured out of the de‐  
fective air conditioner compressor, and 100 cm3 oil was pour‐  
ed out of the replacement air conditioner compressor (a small  
quantity of refrigerant oil remains in the air conditioner com‐  
pressor), pour 50 cm3 refrigerant oil into the replacement air  
conditioner compressor (the refrigerant oil previously poured  
from the air conditioner compressor spare part may be used).  
Different refrigerant oils and volumes for different air condi‐  
tioner compressors ⇒ Heating, air conditioning; Rep. gr. 00 ;  
Technical data .  
If quite a large amount of refrigerant oil was poured out of the  
defective air conditioner compressor (more than approx. 50  
cm 3), the remaining refrigerant oil can also be poured in the  
evaporator or reservoir/receiver/inner heat exchanger ⇒ Heat‐  
ing, air conditioning; Rep. gr. 87 ; Refrigerant circuit; System  
overview - refrigerant circuit .  
All  
lk  
– Renew restrictor (only if installed in this refrigerant circuit).  
– Assemble the refrigerant circuit, evacuate and charge  
⇒ page 129 .  
1.5.5  
Renewing air conditioner compressor  
due to leaks or internal damage  
♦ Observe the general information about renewing components  
⇒ “1.5.1 General information about renewing components”,  
page 79  
Vehicles with high-voltage system (hybrid vehicles)  
– Observe the risk category of the high-voltage system ⇒ Rep.  
gr. 00 ; Risk category of the high-voltage system .  
– Observe safety precautions when working on the high-voltage  
system  
⇒ “1.5 Safety measures for working on vehicles with high-volt‐  
age system”, page 3 .  
– Observe safety precautions when working in the vicinity of  
high-voltage components  
⇒ “1.6 Safety precautions when working in the vicinity of high-  
voltage components”, page 4 .  
All vehicles  
Renew air conditioner compressor e.g. owing to noise from the  
air conditioner compressor or lack of performance.  
– Drain refrigerant circuit ⇒ page 129 .  
– Remove air conditioner compressor ⇒ Heating, air condition‐  
ing; Rep. gr. 87 ; Air conditioner compressor .  
– Clean refrigerant circuit (flush with R1234yf refrigerant)  
⇒ “1.6 Cleaning refrigerant circuit”, page 92 .  
1. Refrigerant circuit  
87  
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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 .  
lk  
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  
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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 .  
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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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lk  
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.  
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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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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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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.  
lk  
♦ 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 .  
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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  
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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  
101  
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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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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
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  
105  
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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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Air conditioning systems with refrigerant R1234yf - General information - Edition 07.2017  
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-  
Remove 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 flushing, install a  
new desiccant bag/car‐  
tridge.  
♦ Adapter - VAS 6338/48- for air con‐  
ditioner service station  
After flushing, install a  
new expansion valve.  
1. Refrigerant circuit  
107  
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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-  
Remove 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 flushing, 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 flushing, 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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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- .  
Remove 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 flushing, install a  
new desiccant bag/car‐  
tridge.  
High pressure side adapter - VAS  
6338/3-  
After flushing, install a  
new expansion valve.  
If a Showa condenser  
is fitted, leave the re‐  
ceiver fitted and flush  
the refrigerant circuit.  
After flushing, 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- .  
Removedesiccant 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 flushing, install a  
new dryer cartridge.  
♦ High pressure side adapter  
- VAS 6338/3-  
After flushing, 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- .  
Removereservoir (dry‐  
er), and bridge refriger‐  
ant pipes.  
Start “Basic 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 flushing, install a  
new reservoir.  
1. Refrigerant circuit  
109  
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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  
Remove 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 flushing, install a  
new desiccant bag/car‐  
tridge.  
♦ High pressure side adapter  
- VAS 6338/3-  
After flushing, 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 flushing, 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.  
Replace shut-off  
♦ High pressure side adapter  
- VAS 6338/3-  
Canbe flushed.  
After flushing, 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  
Removerestrictor in re‐  
frigerant line to heat ex‐  
changer for high-volt‐  
age battery, and drill it  
out (see notes below)  
⇒ page 112 .  
Remove desiccant  
bag/cartridge and seal  
receiver.  
After flushing, 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-  
Canbe flushed.  
After flushing, install a  
new receiver.  
After flushing, install a  
new expansion valve.  
Receiver with desic‐  
cant bag or cartridge  
Remove desiccant  
bag/cartridge and seal  
receiver.  
After flushing, 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  
Remove 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 flushing, install a  
new desiccant bag/car‐  
tridge.  
♦ High pressure side adapter  
- VAS 6338/3-  
After flushing, 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- .  
Removedesiccant 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 flushing, install a  
new dryer cartridge.  
High pressure side adapter - VAS  
6338/3-  
After flushing, 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-  
Remove 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 flushing, install a  
new desiccant bag/car‐  
tridge.  
♦ Adapter - VAS 6338/48- for air condi‐  
tioner service station  
After flushing, 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- .  
Removedesiccant 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 flushing, 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 flushing, 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- .  
Remove 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 flushing, install a  
new desiccant bag/car‐  
tridge.  
♦ High pressure side adapter  
- VAS 6338/3-  
After flushing, 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 flushing, 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- .  
Removedesiccant 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 flushing, 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 flushing, 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  
Receiver 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 flushing, install a  
new receiver.  
♦ High pressure side adapter  
- VAS 6338/3-  
After flushing, 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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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  
Remove 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 flushing, install a  
lk  
new desiccant bag/car‐  
♦ Adapter - VAS 6338/48- for  
air conditioner service sta‐  
tion  
tridge.  
After flushing, 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 flushing, 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  
Remove 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 flushing, install a  
new desiccant bag/car‐  
tridge.  
♦ Adapter - VAS 6338/48- for  
air conditioner service sta‐  
tion  
After flushing, 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 flushing, 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-  
Vehicles with Showa  
condensers:  
After flushing, install a  
new expansion valve.  
Adapter - VAS  
Flush desiccant car‐  
tridge also.  
6338/48- for air condi‐  
tioner service station  
After flushing, 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 flushing, install a  
new expansion valve.  
Adapter - VAS  
Removedesiccant bag  
and seal receiver.  
6338/48- for air condi‐  
tioner service station  
After flushing, 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-  
Removedesiccant bag  
and seal receiver.  
After flushing, 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.  
Removeand 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 flushing, 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 vehicles with 1  
evaporator system,  
flush once.  
On vehicles 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.  
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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  
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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.  
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– 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.  
– The vehicle-specific workshop manual deems it necessary af‐  
ter replacement of certain components ⇒ Heating, air condi‐  
tioning; Rep. gr. 87 ; Refrigerant circuit, System overview -  
refrigerant circuit .  
Note  
Certain contaminants and old refrigerant oil are difficult or impos‐  
sible to remove from the refrigerant circuit with compressed air or  
nitrogen. These contaminants can be removed, for example, by  
flushing with refrigerant R1234yf  
lk  
⇒ “1.6 Cleaning refrigerant circuit”, page 92 .  
♦ Blow through refrigerant circuit with compressed air or nitro‐  
gen  
⇒ “1.6.10 Blowing through refrigerant circuit with compressed  
air or nitrogen”, page 124  
1. Refrigerant circuit  
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1.6.10  
Blowing through refrigerant circuit with  
compressed air or nitrogen  
Note  
Vehicles with refrigerant lines that do not have a thread on  
which to connect adapter - 1785- require e.g. a compressed  
air gun with rubber nozzle or an adapter from adapter case for  
VW/Audi passenger vehicles to blow out individual compo‐  
nents. When using a compressed air gun with rubber nozzle,  
be particularly careful not to damage the connections (do not  
crush or scratch them).  
The evaporator should be blown through from the connection  
to the low pressure side (large diameter), with the expansion  
valve or restrictor removed.  
Always blow out components against the direction of refriger‐  
ant flow (or flush with R1234yf refrigerant).  
Examine the expansion valve; renew if dirty or corroded.  
If there are dark sticky deposits in the components, and these  
cannot be removed with compressed air, flush these compo‐  
nents with refrigerant R1234yf or renew.  
Thin, light grey deposits on the insides of pipes do not impair  
the function of the components.  
After blowing out, renew the receiver (desiccant cartridge) or  
reservoir and restrictor. In cases where condensers have a  
drying agent cartridge in the integrated receiver, this drying  
agent cartridge must be renewed.  
lk  
On vehicles having condensers with an integrated receiver/  
desiccant cartridge which cannot be renewed separately or  
which are not available as a replacement part, the condenser  
must be renewed after flushing the refrigerant circuit ⇒ Elec‐  
tronic parts catalogue and ⇒ Heating, air conditioning; Rep.  
gr. 87 ; Refrigerant circuit; System overview - refrigerant cir‐  
cuit (vehicle-specific workshop manual).  
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.  
After blowing out the refrigerant circuit:  
– Renew these vehicle-specific components (restrictor and res‐  
ervoir, expansion valve and receiver / dryer cartridge) ⇒  
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;  
System overview - refrigerant circuit (vehicle-specific work‐  
shop manual) and ⇒ Electronic parts catalogue  
– Depending on complaint, renew air conditioner compressor ⇒  
Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;  
System overview - refrigerant circuit (vehicle-specific work‐  
shop manual) and ⇒ Electronic parts catalogue or drain  
remaining refrigerant oil from removed air conditioner com‐  
pressor ⇒ “1.5 Renewing components”, page 79 and refill with  
requisite amount of fresh refrigerant oil ⇒ Heating, air condi‐  
tioning; Rep. gr. 00 ; Technical data (vehicle-specific work‐  
shop manual) and ⇒ Heating, air conditioning; Rep. gr. 00 ;  
Technical data; Refrigerant oil .  
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