Get Air conditioning system -> 2.12 Cleaning refrigerant circuit Guide for Volkswagen Touran 4 Door Second Generation (2015-2022)

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

Note

♦ Stored in the air conditioner service station is a function via

which it is switched to a specific operating mode when deac‐

tivated. The whole refrigerant is extracted from the charge

hoses into the air conditioner service station with this function.

♦ If the handwheels of the two service couplings are not un‐

screwed when this function is activated, refrigerant could be

extracted from the vehicle's refrigerant circuit.

– Extract the refrigerant from the two charge hoses using the air

conditioner service station as instructed in the relevant oper‐

ating manual ⇒ Operating instructions of air conditioner serv‐

ice station .

Note

♦ If, on an air conditioner service station with a service coupling

that does not vent to the outside, this process takes longer

than approx. 2 minutes or quite a large amount of refrigerant

is extracted, this suggests that there is a fault in one of the

valves in a service connection.

♦ If, on an air conditioner service station with a service coupling

that does vent to the outside, this process takes longer than

approx. 2 minutes, this suggests that there is a fault in one of

the valves in a service coupling.

Note

Erroneous extraction from vehicle's refrigerant circuit.

– First unscrew (close) the handwheels of the quick-release

coupling adapters.

– Then extract the refrigerant from the two charge hoses using

the air conditioner service station.

– Switch off the air conditioner service station (and isolate it from

the power supply if necessary) ⇒ Operating instructions air

conditioner service station .

– Separate the quick-release couplings from the service con‐

nections of the refrigerant circuit.

– Screw the sealing caps on the service connections (see vehi‐

cle-specific refrigerant circuit) ⇒ Heating, air conditioning;

Rep. gr. 87 ; Refrigerant circuit; System overview - refrigerant

circuit .

2.9

Charging refrigerant in reservoir

– Connect the cylinder with fresh R1234yf refrigerant to the

service coupling on the high pressure side of the air condi‐

tioner service station ⇒ Operating instructions air conditioner

service station .

– Perform a gas analysis on the refrigerant (from the cylinder

supplied) with which the system is to be charged using the air

conditioner service station

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

•

The procedure described in the operating manual for your air

conditioning service station is to be followed ⇒ Operating

manual for air conditioner service station .

2. Working with air conditioner service station

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

CAUTION

Risk of explosion from overfilling refrigerant reservoirs.

Refrigerant can expand and cause reservoirs to burst if they are

overfilled.

– Use a refrigerant tank with safety valve.

– Never exceed the permissible fill level of the refrigerant tank.

Note

Depending on the version of air conditioner service station and

the measures to be performed, there is a minimum volume of re‐

frigerant, refrigerant oil and UV leak detection additive that must

be in the respective supply tank of the air conditioner service sta‐

tion ⇒ Operating instructions air conditioner service station

2.10

Emptying air conditioner service station

Note

♦ If it is necessary to discharge the air conditioner service station

(e.g. because contaminated refrigerant was extracted), all fil‐

ters and dryers must be renewed (do not remove filter and

dryer from the air-tight transport package until immediately

before installation to keep absorption of moisture as low as

possible).

♦ If it is necessary to empty the air conditioner service station

(e.g. because certain measures have to be performed on the

air conditioner service station and the refrigerant that has been

or is to be extracted from the air conditioner service station

complies with the specifications (is not contaminated), it can

be filled into a recycling cylinder, if necessary, and then reused

⇒ Operating instructions air conditioner service station .

♦ Refrigerant cylinders that have been charged with contamina‐

ted or used refrigerant are referred to as “recycling cylinders”

or “R cylinders”.

♦ Always evacuate recycling cylinders before the first filling (re‐

frigerant cylinders containing air must not be filled with refrig‐

erant).

♦ Different types of refrigerant must not be mixed together (mix‐

tures of refrigerant cannot be recycled, but must be disposed

of instead). If the composition of the contents in the cylinder is

not clear, the gas processing / gas disposal company must be

informed of this

⇒ “2.13 Filling contaminated refrigerant in a recycling cylinder

for analysis, processing or disposal”, page 161 and

⇒ “6.2.17 Returning contaminated R1234yf refrigerant for

analysis, processing or disposal”, page 25 .

CAUTION

Risk of explosion from overfilling refrigerant reservoirs.

Refrigerant can expand and cause reservoirs to burst if they are

overfilled.

– Use a refrigerant tank with safety valve.

– Never exceed the permissible fill level of the refrigerant tank.

There are various ways to empty an air conditioner service sta‐

tion , observe the operating instructions of the air conditioner

154

Rep. gr.87 - Air conditioning system

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

service station ⇒ Operating instructions air conditioner service

station .

– Drain the refrigerant from the air conditioner service station to

be emptied into a different air conditioner service station , ob‐

serving the operating instructions of the air conditioner service

station to do so ⇒ Operating instructions air conditioner serv‐

ice station and

⇒ “2.13 Filling contaminated refrigerant in a recycling cylinder

for analysis, processing or disposal”, page 161 .

2.11

Cleaning electrical air conditioning com‐

pressor

Vehicles with high-voltage system

Observe the additional warnings for working on vehicles with

high-voltage system ⇒ Electrical system; Rep. gr. 93 ; General

warnings for work on the high-voltage system .

If repair work in the vicinity of high-voltage components and ca‐

bles is necessary, carry out a visual check for damage on high-

voltage components and cables, and observe the warnings ⇒

Electrical system; Rep. gr. 93 ; General warnings for work on the

high-voltage system .

If repair work on high-voltage components is necessary, de-en‐

ergise the high-voltage system ⇒ Electrical system; Rep. gr. 93 ;

De-energising high-voltage system , and “observe the general

warnings for work on the high-voltage system” ⇒ Electrical sys‐

tem; Rep. gr. 93 ; General warnings for work on the high-voltage

system .

Flushing air conditioner compressor

Note

♦ On an electrical air conditioning compressor, the refrigerant oil

cannot be poured out (as there is no oil drain plug), i.e. the

design makes no allowance for the drainage of oil

♦ With an electrical air conditioning compressor, the refrigerant

oil is to be removed in the direction of flow by flushing (flushing

in the opposite direction of flow is not possible due to the in‐

tegrated valves).

♦ The air conditioner compressor must be positioned for flushing

so that the connection for the refrigerant line on the high pres‐

sure side is at the lowest point possible.

2. Working with air conditioner service station

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

1 - Air conditioner service sta‐

tion

❑ With electronics and

flushing program, air

conditioner service sta‐

tion with flushing device

⇒ Electronic parts cata‐

logue .

❑ 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 2 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 to connection for

low pressure side on air condi‐

tioner compressor

❑ Different versions de‐

pending on vehicle

⇒ “1.6.8 Adapters for

setting up flushing cir‐

cuits”, page 105

❑ The item to be used be‐

tween the refrigerant

hose -2- and adapter -3- is adapter - VAS 6338/48- .

❑ From adapter case VW/Audi passenger vehicle set

4 - Refrigerant line

❑ For connection of air conditioner compressor to adapter ⇒ Item 3 (page 156)

5 - Electrical air conditioner compressor

❑ Flush the air conditioner compressor in normal direction of flow (from low pressure inlet to high pressure

outlet)

❑ In order to flush as much refrigerant oil out of the air conditioner compressor as possible, make sure that

the high pressure outlet of the air conditioner compressor is in the lowest position possible

Note

♦ Depending on the air conditioner

compressor, a new air condition‐

er compressor might be filled

with quite a large amount of re‐

frigerant oil (see manufacturer

plate on air conditioner compres‐

sor and

⇒ “5.2 Refrigerant oil capacities”,

page 15 ).

156

Rep. gr.87 - Air conditioning system

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

♦ On a new air conditioner com‐

pressor filled with more than

150 cm³, pour out as much re‐

frigerant oil as possible before

flushing.

♦ Reason: The oil volume to be

displaced in one work step may

be restricted depending on the

version of air conditioner service

station .

Note

If the clean refrigerant oil is poured

out of a new air conditioner com‐

pressor into a clean container and

this is subsequently sealed air-tight,

the refrigerant oil can be re-used to

top-up the refrigerant oil volume in

the circuit.

6 - Refrigerant line

❑ For connection of air conditioner compressor to adapter ⇒ Item 7 (page 157)

❑ Use a refrigerant line e.g. with part number 7L6 820 721 BF to set-up the flushing circuit ⇒ Electronic

parts catalogue

7 - Adapter for connection on high pressure side of air conditioner compressor

❑ Different versions depending on vehicle ⇒ “1.6.8 Adapters for setting up flushing circuits”, page 105

❑ From adapter case VW/Audi passenger vehicle set

8 - 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.

9 - 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 layout of the air conditioner service station and the flushing device for refrigerant

circuits, there may be a service coupling for refrigerant circuits fitted at the outlet and in some cases at

the inlet of the flushing device. If a service connection with a valve is installed to the outlet of the flushing

device, this valve must be opened completely when the service coupling is connected. If the valve is not

opened completely, it restricts the refrigerant flow.

❑ If there is a connection for a service coupling fitted at the inlet of the flushing device, the inlet must be

adapted to allow for the refrigerant hose coming from the vehicle to be connected directly.

Note

A service coupling and a valve in the

inlet of the flushing device restrict

the refrigerant flow from the vehicle

into the flushing device.

10 - 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.

2.12

Cleaning refrigerant circuit

– Perform preparatory measures for cleaning (flushing with

R1234yf refrigerant)

2. Working with air conditioner service station

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Air conditioning system -> 2.12 Cleaning refrigerant circuit for Your Volkswagen Touran 4 Door Second Generation (2015-2022)

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